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Toyota Camry Manual

Toyota Camry Manual

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AC–1

AIR CONDITIONING SYSTEM

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AIR CONDITIONING SYSTEM

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Page 1 AC–1 AIR CONDITIONING SYSTEM – AIR CONDITIONING SYSTEM...
Page 2 R 134a air condi– tioning systems. Always use genuine Toyota R1 34a air conditioning oil N D – OIL 8, made expressly for use with R 1 34a. If even a small amount of the wrong oil is changed, it will result in clouding of the refrigerant.
Page 3 0–rings and seals used for conventional R12 air conditioning systams cannot be used for R134a air conditioning systems. Always use genuine Toyota R 134a system 0–rings and seals for R 1 34a air conditioning systems. If O–rings and/or seals for R1 2 air conditioning sys–...
Page 4: Ac–45
AC–4 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION SERVICE TOOLS FOR R134a AIR CONDITIONER When servicing R134a air conditioning systems always use the R134a dedicated manifold gauges, gas leak detector and vacuum pump adaptor. USE MANIFOLD GAUGES FOR R134a AIR CONDITI– ONER Always use R134a dedicated manifold gauges to pre–...
Page 5 AC–5 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION HANDLING PRECAUTIONS FOR REFRIGERANT DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cool water.
Page 6 AC–6 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION CAUTION: Be sure to connect both the high and low pressure quick–connectors onto the A/C system when eva– cuating. If only one side is connected, the system would be open to atmosphere through the other connector, making it impossible to maintain vacuum.
Page 7 AC–7 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to deploy, possibly leading to a serious acci– dent. During removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the RS section before performing the operation.
Page 8 AC–8 AIR CONDITIONING SYSTEM – DESCRIPTION DESCRIPTION PARTS LOCATION...
Page 9 AC–9 AIR CONDITIONING SYSTEM – DESCRIPTION...
Page 10 AC–10 AIR CONDITIONING SYSTEM – DESCRIPTION ELECTRICAL WIRING DIAGRAM (Lever Type On 5S–FE Engine Model)
Page 11 AC–11 AIR CONDITIONING SYSTEM – DESCRIPTION...
Page 12 AC–12 AIR CONDITIONING SYSTEM – DESCRIPTION (Push Button Type On 5S–FE Engine Model)
Page 13 AC–13 AIR CONDITIONING SYSTEM – DESCRIPTION...
Page 14 AC–14 AIR CONDITIONING SYSTEM – DESCRIPTION (Lever Type On 1 MZ–FE Engine Model)
Page 15 AC–15 AIR CONDITIONING SYSTEM – DESCRIPTION...
Page 16 AC–16 AIR CONDITIONING SYSTEM – DESCRIPTION (Push Button Type On 1 MZ–FE Engine Model)
Page 17 AC–17 AIR CONDITIONING SYSTEM – DESCRIPTION...
Page 18 AC–18 AIR CONDITIONING SYSTEM – DESCRIPTION DAMPERS POSITION...
Page 19 AC–19 AIR CONDITIONING SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 07110–58060 Air Conditioner Service Tool Set (07117–58060) Refrigerant Drain Service Valve (07117–58070) T–Joint Discharge (diam. 16 mm) (07117–58080) Quick Coupler Suction (diam. 13 mm) (07117–58090) Quick Coupler (07117–78050) Refrigerant Charging Gauge Discharge (Red) (07117–88060) Refrigerant Charging Hose Suction (Blue)
Page 20 AC–20 AIR CONDITIONING SYSTEM – PREPARATION RECOMMENDED TOOL 09082–00050 TOYOTA Electrical Tester Set LUBRICANT Capacity Classification Item ND–OIL 8 or equivalent Compressor oil 10 cc (0.34 fl.oz.) When replacing receiver When replacing condenser 40 cc (1.4 f I.oz.) 40 cc (1.4 fl.oz.)
Page 21 AC–21 AIR CONDITIONING SYSTEM – USE OF MANIFOLD GAUGE SET USE OF MANIFOLD GAUGE SET MANIFOLD GAUGE SET INSTALLATION CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. CONNECT QUICK CONNECTORS TO CHARGING HOSES Tighten the nuts by hand.
Page 22 AC–22 AIR CONDITIONING SYSTEM – TROUBLESHOOTING TROUBLESHOOTING Use the table below to help you find the cause of problem. The numbers indicate the priority of the likely cause of the problem. Check each rt in order. If necessary, replace these parts. AC–30 AC–60 AC–29...
Page 23 AC–23 AIR CONDITIONING SYSTEM – TROUBLESHOOTING AC–47 AC–49 AC–45 AC–53 AC–36 AC–36 AC–58 AC–55 AC–56 AC–67 AC–66 AC–57 AC–59...
Page 24 AC–24 AIR CONDITIONING SYSTEM – TROUBLESHOOTING REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. (See ”USE OF MANIFOLD GAUGE SET” on page AC–21) Read the manifold gauge pressure when the following conditions are established: (a) Temperature at the air inlet with the switch set at RECIRC is 30 –...
Page 25 AC–25 AIR CONDITIONING SYSTEM – TROUBLESHOOTING MOISTURE PRESENT IN REFRIGERATION SYSTEM Condition: Periodically cools and then fails to cool Symptom seen in Probable cause Diagnosis Remedy refrigeration system During operation, prea– Moisture entered in re– Drier in oversaturated (1) Replace receiver/drier sure on low pressure frigeration system state...
Page 26 AC–26 AIR CONDITIONING SYSTEM – TROUBLESHOOTING POOR CIRCULATION OF REFRIGERANT Condition: Insufficient cooling Symptom seen in Probable cause Diagnosis Remedy refrigeration system Pressure low on both Refrigerant flow ob– R e c e i v e r Replace receiv- low and high pressure structed by dirt in re–...
Page 27 AC–27 AIR CONDITIONING SYSTEM – TROUBLESHOOTING REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER Condition: Does not cool sufficiently Symptom seen in Probable cause Diagnosis Remedy refrigeration system Pressure too high on Unable to develop suffi– Excessive refrigerant in (1) Clean condenser (2) Check fan motor oper–...
Page 28 AC–28 AIR CONDITIONING SYSTEM – TROUBLESHOOTING EXPANSION VALVE IMPROPERLY MOUNTED/HEAT SENSING TUBE DEFECTIVE (OPENS TOO WIDE) Condition: Insufficient cooling Symptom seen in Probable cause Diagnosis Remedy refrigeration system Pressure too high on Trouble in expansion Excessive refrigerant in (1) Check heat sensing tube installed condition both low and high valve or heat sensing...
Page 29 AC–29 AIR CONDITIONING SYSTEM – REFRIGERANT VOLUME REFRIGERANT VOLUME REFRIGERANT VOLUME INSPECTION RUN ENGINE AT IDLE SPEED OPERATE A/C AT MAXIMUM COOLING FOR A FEW MINUTES INSPECT AMOUNT OF REFRIGERANT OBSERVE THE SIGHT GLASS ON THE LIQUID TUBE. Amount of refrigerant Remedy Item Symptom...
Page 30 AC–30 AIR CONDITIONING SYSTEM – DRIVE BELT TENSION DRIVE BELT TENSION DRIVE BELT TENSION INSPECTION INSPECT DRIVE BELT’S INSTALLATION CONDI– TION Check that the drive belt fits properly in the ribbed grooves. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt ten– sion.
Page 31 AC–31 AIR CONDITIONING SYSTEM – REFRIGERANT LINES REFRIGERANT LINES TIGHTENING TORQUE OF REFRIGERATION LINES ON–VEHICLE INSPECTION INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak tester, check for leakage of refriger– ant.
Page 32 AC–32 AIR CONDITIONING SYSTEM – REFRIGERANT LINES REFRIGERANT LINES REPLACEMENT DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM (See page AC–21) REPLACE FAULTY TUBE OR HOSE HINT: Cap the open fittings immediately to keep mois– ture or dirt out of the system. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torque tighter than the specified torque.
Page 33 AC–33 AIR CONDITIONING SYSTEM – AIR CONDITIONING UNIT AIR CONDITIONING UNIT A/C UNIT REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE DISCONNECT WATER HOSES FROM HEATER RA–...
Page 34 AC–34 AIR CONDITIONING SYSTEM – AIR CONDITIONING UNIT 10. REMOVE A/C UNIT (a) Disconnect connectors from the unit. (b) Remove the 3 nuts and the A/C unit. A/C UNIT INSTALLATION INSTALL A/C UNIT (a) Install the A/C unit with the 3 nuts. (b) Connect connectors.
Page 35 AC–35 AIR CONDITIONING SYSTEM – BLOWER UNIT BLOWER UNIT BLOWER UNIT REMOVAL REMOVE GLOVE COMPARTMENT (See page BO–108) REMOVE ECU AND ECU BRACKET REMOVE CONNECTOR BRACKET (a) Disconnect the connector from the connector brack– (b) Remove the 2 screws and the bracket. REMOVE BLOWER UNIT (a) Disconnect the connector from the blower unit.
Page 36 AC–36 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR ON–VEHICLE INSPECTION Magnet Clutch: MAKE THE FOLLOWING VISUAL CHECKS: Leakage of grease from the clutch bearing. Signs of oil on the pressure plate or rotor. Repair or replace, as necessary. INSPECT MAGNET CLUTCH BEARING FOR NOISE (a) Start engine.
Page 37 AC–37 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR REMOVAL 5S–FE Engine Model: RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK”...
Page 38 AC–38 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR REMOVAL 1 MZ–FE Engine Model: RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK”...
Page 39 AC–39 AIR CONDITIONING SYSTEM – COMPRESSOR DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) DISCONNECT DISCHARGE HOSE AND SUCTION HOSE FROM COMPRESSOR DISCONNECT CONNECTOR FROM MAGNET CLUTCH REMOVE DRIVE BELT Loosen the pivot bolt and adjusting lock bolt and remove the drive belt.
Page 40 AC–40 AIR CONDITIONING SYSTEM – COMPRESSOR MAGNET CLUTCH DISASSEMBLY REMOVE PRESSURE PLATE (a) Using SST and socket wrench, remove the shaft bolt. SST 07112 – 76060 (b) Install a SST on the pressure plate. SST 07112–66040...
Page 41 AC–41 AIR CONDITIONING SYSTEM – COMPRESSOR (c) Using SST and socket wrench, remove the pressure plate. SST 07112–76060 (d) Remove the shims from the pressure plate. REMOVE ROTOR (a) Using SST, remove the snap ring. SST 07114–84020 CAUTION: Do not spread the point of SST widely. Max width: 23.1 mm (b) Using a plastic hammer, tap the rotor off the shaft.
Page 42 AC–42 AIR CONDITIONING SYSTEM – COMPRESSOR (b) Using a SST, remove the snap ring. SST 07114–84020 (c) Remove the stator. MAGNET CLUTCH ASSEMBLY INSTALL STATOR (a) Install the stator on the compressor. (b) Using SST, install the new snap ring. SST 07114 –84020 NOTICE: The snap ring should be installed so that its beveled side faces up.
Page 43 AC–43 AIR CONDITIONING SYSTEM – COMPRESSOR (c) Using SST and torque wrench, fasten the magnet clutch lead wire to the cylinder block. Torque: 3.4 N–m (35 kgf.cm, 30 in.–lbf) SST 07110–61050 INSTALL ROTOR (a) Install the rotor on the compressor shaft. (b) Using SST, install the new snap ring.
Page 44 AC–44 AIR CONDITIONING SYSTEM – COMPRESSOR CHECK CLEARANCE OF MAGNET CLUTCH (a) Set the dial – gauge to the pressure plate of the magnet clutch. (b) Connect the magnet clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor, whenconnect the negative (–) terminal of the battery.
Page 45 AC–45 AIR CONDITIONING SYSTEM – RECEIVER RECEIVER ON–VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak tester, check for leakage. If there is leakage, check the tightening torque at the joints. RECEIVER REMOVAL DICHARGER REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) REMOVE 2 LIQUID TUBES FROM RECEIVER Remove the 2 bolts and the both tubes from the...
Page 46 AC–46 AIR CONDITIONING SYSTEM – RECEIVER RECEIVER INSTALLATION INSTALL RECEIVER INTO RECEIVER HOLDER Install the receiver into the receiver, holder with the bolt. INSTALL 2 LIQUID TUBES TO RECEIVER Install 2 liquid tubes to the receiver with 2 bolts. Torque: 5.5 N–m (55 kgf–cm, 48 in.–lbf) NOTICE: Do not remove the caps until the tubes are connected.
Page 47 AC–47 AIR CONDITIONING SYSTEM – CONDENSER CONDENSER ON–VEHICLE INSPECTION INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers.
Page 48 AC–48 AIR CONDITIONING SYSTEM – CONDENSER REMOVE CONDENSER Remove the 2 bolts and lean the radiator backward, then remove the cond enser. CONDENSER INSTALLATION INSTALL CONDENSER Install the condenser with the 2 bolt. INSTALL LIQUID TUBES Install both tubes with the 2 bolts. Specified torque: 9.8 N–m (100 kgf–cm, 7 ft–lbf) NOTICE: Do not remove caps until the tube is installed.
Page 49 AC–49 AIR CONDITIONING SYSTEM – EVAPORATOR EVAPORATOR EVAPORATOR REMOVAL DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) REMOVE BLOWER UNIT (See page AC–35) REMOVE EVAPORATOR COVER (a) Remove 2 bolts for the liquid and suction tube. (b) Remove 8 screws and evaporator cover. REMOVE EVAPORATOR (a) Pull and remove the evaporator.
Page 50 AC–50 AIR CONDITIONING SYSTEM – EVAPORATOR EVAPORATOR INSTALLATION INSTALL REMOVAL PARTS Install the removal parts in reverse order of removal procedure. HINT: The tightening torque for the bolt used to install the expantion valve on the evaporator is shown below. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) The tightening torque for the bolts used to install the liquid and suction tube is shown below.
Page 51 AC–51 AIR CONDITIONING SYSTEM – HEATER RADIATOR HEATER RADIATOR HEATER RADIATOR REMOVAL REMOVE HEATER PROTECTOR Remove the 2 clips and the heater protector. REMOVE HEATER RADIATOR (a) Remove the 3 screws and the 3 clamps. (b) Disconnect the heater pipes. (c) Pull the heater radiator out.
Page 52 AC–52 AIR CONDITIONING SYSTEM – WATER VALVE WATER VALVE WATER VALVE REMOVAL DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE DISCONNECT WATER HOSE FROM WATER VALVE REMOVE WATER VALVE (a) Disconnect the water hose from the heater radiator pipe.
Page 53 AC–53 AIR CONDITIONING SYSTEM – EXPANSION VALVE EXPANSION VALVE ON–VEHICLE INSPECTION CHECK QUANTITY OF GAS DURING REFRIGERA– TION CYCLE INSTALL MANIFOLD GAUGE SET RUN ENGINE Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 – 1.53 MPa (14 –...
Page 54 AC–54 AIR CONDITIONING SYSTEM – AIR SWITCHING VALVE (ASV) AIR SWITCHING VALVE (ASV) VACUUM HOSE CIRCUIT (5S–FE ENGINE MODEL) ASV INSPECTION (5S–FE ENGINE MODEL) CHECK VACUUM CIRCUIT CONTINUITY IN ASV BY BLOWING AIR INTO PIPES (a) Connect the ASV terminals to the battery terminals as illustrated.
Page 55 AC–55 AIR CONDITIONING SYSTEM – BLOWER MOTOR BLOWER MOTOR BLOWER MOTOR REMOVAL REMOVE INSTRUMENT LOWER PANEL AND UNDER COVER NO. 2 (See page BO–108) REMOVE CONNECTOR BRACKET Remove the 2 screws and the bracket REMOVE MOTOR (a) Disconnect the connector. (b) Remove the 3 screws and the motor.
Page 56 AC–56 AIR CONDITIONING SYSTEM – CONDENSER FAN MOTOR CONDENSER FAN MOTOR CONDENSER FAN MOTOR INSPECTION 5S–FE ENGINE MODEL: DISCONNECT CONNECTOR INSPECT CONDENSER FAN MOTOR Connect positive (+) lead from battery and negative (–) lead to terminals, then check that the condenser fan motor operates smoothly.
Page 57 AC–57 AIR CONDITIONING SYSTEM – AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR REMOVAL REMOVE GLOVE COMPARTMENT (See page BO–108) REMOVE ECU AND ECU BRACKET REMOVE SERVOMOTOR (a) Disconnect the connector. (b) Remove the 2 screws and the servomotor. AIR INLET SERVOMOTOR INSPECTION INSPECT SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to...
Page 58 AC–58 AIR CONDITIONING SYSTEM – AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR REMOVAL REMOVE INSTRUMENT LOWER FINISH PANEL AND AIR DUCT (See page BO–108) REMOVE AIR DUCT NO. 2 REMOVE SERVOMOTOR (a) Disconnect the connector. (b) Remove the 2 screws and the servomotor. AIR OUTLET SERVOMOTOR INSPECTION INSPECT SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to...
Page 59 AC–59 AIR CONDITIONING SYSTEM – BLOWER RESISTOR BLOWER RESISTOR BLOWER RESISTOR REMOVAL REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO–108) REMOVE BLOWER RESISTOR (a) Disconnect the connector from the resistor. (b) Remove the 2 screws and the resistor. BLOWER RESISTOR INSPECTION INSPECT BLOWER RESISTOR CONTINUITY Continuity Tester connectoin to...
Page 60 AC–60 AIR CONDITIONING SYSTEM – PRESSURE SWITCH PRESSURE SWITCH ON–VEHICLE INSPECTION INSTALL MANIFOLD GAUGE SET (See page AC–21) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 2000 RPM INSPECT PRESSURE SWITCH OPERATION Magnet Clutch Control: (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and negative (–) lead to terminal 1.
Page 61 AC–61 AIR CONDITIONING SYSTEM – PRESSURE SWITCH PRESSURE SWITCH REMOVAL DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the pressure switch from the liquid tube. HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch.
Page 62 AC–62 AIR CONDITIONING SYSTEM – EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR REMOVAL REMOVE EVAPORATOR TEMPERATURE SENSOR Remove the screw and the evaporator temperature sensor (thermistor). EVAPORATOR TEMPERATURE SENSOR INSPECTION Check resistance between terminals of evaporator temperature sensor (thermistor) connector at each temperature.
Page 63 AC–63 AIR CONDITIONING SYSTEM – REVOLUTION DETECTING SENSOR REVOLUTION DETECTING SENSOR ON–VEHICLE INSPECTION DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition swithch is turned “LOCK” position and the negative (–) terminal cable is disconnected from the battery.
Page 64 AC–64 AIR CONDITIONING SYSTEM – RELAY RELAY RELAYS REMOVAL DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery.
Page 65 AC–65 AIR CONDITIONING SYSTEM – RELAY INSPECT HEATER MAIN RELAY CONTINUITY Tester connection to Condition Specified value terminal number 1–3 Continuity Constant 2–4 Apply B + between 4–5 Continuity terminals 1 and 3. If continuity is not as specified, replace the relay. RELAYS INSTALLATION INSTALL RELAYS CONNECT NEGATIVE (–) CABLE TO BATTERY...
Page 66 AC–66 AIR CONDITIONING SYSTEM – AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER A/C AMPLIFIER INSPECTION INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side, as shown in the chart below. Test conditions Ignition switch : ON Temperature control dial : MAX COOL Blower dial: HI Tester connection...
Page 67 AC–67 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY A/C CONTROL ASSEMBLY REMOVAL (See page BO–108) A/C CONTROL ASSEMBLY INSPECTION (ROTARY SWITCH AND PUSH BUTTON TYPE) INSPECT A/C INDICATOR (a) Connect the positive (+) lead from the battery to terminal A–12 and the negative (–) lead to terminal A–4.
Page 68 AC–68 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY INSPECT AIR INLET INDICATOR (a) Connect the positive (+) lead from the battery to terminal A– 12 and the negative (–) lead to terminal A–1. (b) Check that the FRESH and RECIRC indicators light up alternately each time the air inlet control switch button is pressed.
Page 69 AC–69 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY INSPECT MODE CONTROL SWITCH CONTINUITY Tester connection to Switch position Specified value terminal number A11 –Al Continuity FACE A3 – A 1 Continuity FOOT A10 – A1 Continuity FOOT/ oeF A2 – A 1 Continuity A9 –...
Page 70 AC–70 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY INSPECT BLOWER SPEED CONTROL SWITCH CON– TINUITY Terminal B–1 6–8 E–2 B–4 B–5 B–7 B–6 Switch position If continuity is not as specified, replace the switch.
Page 71 AC–71 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY ROTARY SWITCH AND LEVER TYPE: INSPECT A/C SWITCH CONTINUITY Tester connection to Switch position Specified value terminal number OFF. No continuity Continuity 2 – 5 If continuity is not as specified, replace the switch. INSPECT MODE CONTROL SWITCH CONTINUITY Tester connection to Switch position...
Page 72 AC–72 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY Terminal Switch position If continuity is not as specified, replace the switch. A/C CONTROL CABLES ADJUSTMENT ADJUST AIR INLET DAMPER CONTROL CABLE Set the air inlet damper and the control lever to ” FRESH”...
Page 73 AC–73 AIR CONDITIONING SYSTEM – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Refrigerant charge volume Drive belt tention New belt 5S–FE: Used belt New belt 1 MZ– FE: Used belt Idle speed Magnetic clutch no engaged 5S–FE: Magnetic clutch engaged Magnetic clutch noT engaged 1 MZ–...
Page 74 AX1–1 AUTOMATIC TRANSAXLE – A140E AUTOMATIC TRANSAXLE...
Page 75 AX1–2 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION PRECAUTIONS When working with FIPG material, you must observe the following. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. Thoroughly clean all components to remove all the loose material. Clean both sealing surfaces with a non–residue solvent.
Page 76 AX1–3 AUTOMATIC TRANSAXLE – DESCRIPTION SPECIFICATIONS Type of Transaxle Type of Engine Torque Converter Clutch Stall Torque Ratio Torque Converter Clutch Lock–up Mechanism Gear Ratio 1 st Gear 2nd Gear 3rd Gear 0/D Gear Reverse Gear Number of Discs / Plates Transaxle O/D Direct Clutch (Co) Forward Clutch (C,)
Page 77 AX1–4 AUTOMATIC TRANSAXLE – OPERATION OPERATION 0 ..Operating Shift lever Gear Position position Parking Reverse Neutral ” 3rd *2nd ’ Down–shift only–no up–shift...
Page 78 AX1–5 AUTOMATIC TRANSAXLE – OPERATION 1. FUNCTION OF COMPONENTS FUNCTION COMPONENT Connects Overdrive sun gear and overdrive carrier. O/D Direct Clutch (Co) Prevents overdrive sun gear from turning either clockwise or counterclockwise. 0/D Brake (Bo) When transaxle is being driven by engine, connects overdrive sun gear and O/D One–Clutch (Fo) overdrive carrier.
Page 79 AX1–6 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
Page 80 AX1–7 AUTOMATIC TRANSAXLE – OPERATION 2. Hydraulic Control System The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulator, the clutches and brakes, and the governor valve as well as the fluid passages which connect all of these components.
Page 81 AX1–8 AUTOMATIC TRANSAXLE – OPERATION 3. Electronic Control System The electronic control system for controlling the shift timing and the operation of the lock–up clutch is composed of the following three parts: (a) Sensors: These sense the vehicle speed and throttle position and send this data to the ECM in the form of electronic signals.
Page 82 AX1–9 AUTOMATIC TRANSAXLE – OPERATION SYSTEM DIAGRAM...
Page 83 AX1–10 AUTOMATIC TRANSAXLE – OPERATION ARRANGEMENT OF COMPONENTS Functions Components Blinks and warns the driver, while the 0/D main switch is pushed in, when the O/D OFF Indicator Light electronic control circuit is malfunctioning. Selects the Power mode or the Normal mode for shift and lock–up timing. Pattern Select Switch Prevents up shift to the O/D gear if the O/D switch is off.
Page 84 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Toot (09351–32020) Stator Stopper (09351–32130) Handle (09351–32150) Oil Seal Replacer 09843–18020 Diagnosis Check Wire Line pressure 09992–00094 Automatic Transmission Oil Pressure Gauge Set RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set...
Page 85 AX1–12 AUTOMATIC TRANSAXLE – PREPARATION EQUIPMENT Straight edge Check torque converter clutch installation. Vernier calipers Check torque converter clutch installation. Dial indicator or dial indicator with magnetic base Measures drive plate runout. Torque wrench LUBRICANT Capacity Classification Item Automatic transaxle fluid ATF DEXRON (w/o Differential oil) 5.6 liters (5.9 US qts, 4.9 Imp.qts)
Page 86 AX1–13 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR ON–VEHICLE REPAIR VALVE BODY REMOVAL 1. CLEAN TRANSAXLE EXTERIOR To help prevent contamination, clean the exterior of the transaxle. 2. DRAIN TRANSAXLE FLUID Remove the drain plug with SST, and drain the fluid into a suitable container. SST 09043–38100 3.
Page 87 AX1–14 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 7. REMOVE OIL TUBES Pry up the both tube ends with a large screwdriver and remove the four tubes. 8. REMOVE MANUAL DETENT SPRING 9. REMOVE MANUAL VALVE AND MANUAL VALVE BODY 10. REMOVE VALVE BODY Remove the 12 bolts.
Page 88 AX1–15 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY INSTALLATION 1. INSTALL SECOND BRAKE APPLY GASKET 2. INSTALL VALVE BODY (a) While holding the cam down with your hand, slip the cable and into the slot. (b) Bring valve body into place. NOTICE: Be careful not to entangle the solenoid wire.
Page 89 AX1–16 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR (d) Place the detent spring on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) (e) Check that the manual valve lever is touching the center of the detent spring tip roller.
Page 90 AX1–17 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 11. FILL TRANSAXLE WITH ATF Add only about 2 liters of ATF. NOTICE: Do not overfill. Fluid type: ATF DEXRON 12. CHECK FLUID LEVEL (See page AX1–54) THROTTLE CABLE REMOVAL 1. DISCONNECT THROTTLE CABLE (a) Disconnect the cable housing from the bracket.
Page 91 AX1–18 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR THROTTLE CABLE INSTALLATION 1. INSTALL CABLE IN TRANSAXLE CASE (a) Be sure to push it in all the way. (b) Install the retaining plate and the bolt. 2. INSTALL VALVE BODY (See page AX–15) 3.
Page 92 AX1–19 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR DIFFERENTIAL OIL SEAL REMOVAL 1. REMOVE BOTH DRIVE SHAFTS (See page SA–38) 2. REMOVE BOTH SIDE GEAR SHAFT OIL SEALS Using SST, pull out the oil seal. SST 09308–00010 DIFFERENTIAL OIL SEAL INSTALLATION 1. INSTALL LEFT SIDE GEAR SHAFT OIL SEAL (1) Using SST, drive in a new oil seal.
Page 93 AX1–20 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY COMPONENTS...
Page 94 AX1–21 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 1.
Page 95 AX1–22 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 8. REMOVE STARTER (a) Disconnect the connector and nut. (b) Remove the 2 bolts and the starter. 9. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 10. DISCONNECT SOLENOID CONNECTOR 11. DISCONNECT OIL COOLER HOSE 12.
Page 96 AX1–23 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 13. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLT 14. REMOVE 2 BOLT AND CLAMP FROM FRONT FRAME ASSEMBLY 15. REMOVE 3 UPPER TRANSAXLE TO ENGINE BOLT 16. INSTALL ENGINE SUPPORT FIXTURE 17. TIE STEERING GEAR HOUSING TO ENGINE SUP –...
Page 97 AX1–24 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Remove the 2 bolts and nuts from rear exhaust pipe. 21. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET 22. DRAIN DIFFERENTIAL FLUID INTO A SUITABLE CONTAINER 23. REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO.2 24.
Page 98 AX1–25 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 28. REMOVE ENGINE 4 TRANSAXLE MOUNTING BOLTS 29. REMOVE STEERING GEAR HOUSING (a) Remove the 4 bolts and disconnect stabilizer bar bus– hing bracket from the front frame assembly. (b) Remove the 2 bolts and nuts from the steering gear housing.
Page 99 AX1–26 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. REMOVE STIFFENER PLATE (a) Hold the transaxle with a jack. (b) Remove the 3 bolts and stiffener plate. 32. REMOVE REAR END PLATE (a) Remove the 4 bolts. (b) Remove the rear end plate. 33.
Page 100 AX1–27 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 35. REMOVE TRANSAXLE ASSEMBLY Separate transaxle and engine, and lower the trans– axle. 36. REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE TRANSAXLE INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH IN TRA– NSAXLE If the torque converter clutch has been drained and washed, refill with new ATF.
Page 101 AX1–28 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 10 mm head bolt Torque: 46 N–m (470 kgf–cm, 34 ft–lbf) 5. INSTALL TORQUE CONVERTER CLUTCH MOUNT– ING BOLT (a) Clean the threads of the bolts with the gasoline. (b) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equi–...
Page 102 AX1–29 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (d) Torque the nuts. Torque: 36 N–m (370 kgf–cm. 27 ft–lbf) (c) Install the 2 set screws in the right and left fender liners. 9. INSTALL STEERING GEAR HOUSING (a) Install the steering gear housing to the front frame assembly.
Page 103 AX1–30 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 11. INSTALL 3 REAR SIDE ENGINE MOUNTING NUTS Torque: 66 N–m (670 kgf–cm, 48 ft–Ibf) 12. INSTALL FRONT SIDE ENGINE MOUNTING NUT Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) 13. INSTALL DRIVE SHAFT (See page SA–40) 14.
Page 104 AX1–31 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Install the rear exhaust pipe with the 2 bolts and nuts. Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) 20. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) 21.
Page 105 AX1–32 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. CONNECT SHIFT CONTROL CABLE (a) Install the clip to the control cable. (b) Install the nut. (c) Adjust the control cable. (See page AX1–55) 27. CONNECT OIL COOLER HOSE 28. CONNECT SOLENOID CONNECTOR 29.
Page 106 AX1–33 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. CONNECT VEHICLE SPEED SENSOR CONNECTOR 32. INSTALL GROUND TERMINAL w/ Cruise Control System: 33. CONNECT CONNECTOR TO CRUISE CONTROL ACTUATOR 34. INSTALL CRUISE CONTROL ACTUATOR COVER 35. INSTALL THROTTLE CABLE TO ENGINE (a) Torque the nuts.
Page 107 AX1–34 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 38. FILL TRANSAXLE WITH ATF Fluid type: ATF DEXRON Capacity: 5.6 liters (5.9 US gts, 4.9 Imp.gts) 39. CHECK FLUID LEVEL (See page AX1–64) 40. INSPECT FRONT WHEEL ALIGNMENT (See page SA–40) 41.
Page 108 AX1–35 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch. SST 09350–32014 (09351–32020) (c) With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise.
Page 109 AX1–36 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM COMPONENT PARTS LOCATION WIRING DIAGRAM...
Page 110 AX1–37 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM ELECTRIC CONTROL COMPONENTS INSPECTION 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each termi– nals. HINT: Do not disconnect the ECU connector. Voltage (V) Measuring condition Terminal Connector Ignition switch ACC position Ignition switch ON position Depress brake pedal...
Page 111 AX1–38 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM 3. INSPECT KEY INTERLOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5–16.50 (c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid.
Page 112 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TROUBLESHOOTING...
Page 113 AX1–40 AUTOMATIC TRANSAXLE – TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING For troubleshooting using a volt/ohm meter, see page AX1–40142. HOW TO PROCEED WITH TROUBLESHOOTING USING VOLT OHM METER 1. CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 114 AX1–41 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 11. MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is confirmed in the diagnostic trouble code check, perform inspection according to the inspection order in the matrix chart of problem symptoms. Perform diagnosis of each circuit or part in the order shown in the Matrix Chart.
Page 115 See the indicated pages for detailed Customer Problem Analysis explanations. AX1–43 Step 2, 5, 12, 15: Diagnostic steps permitting the use of the TOYOTA Check and Clear Diagnostic Trouble. Codes (Precheck) hand–held tester or TOYOTA Precheck) brake–out–box. AX1–44–AX1–46...
Page 116 AX1–43 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS...
Page 117 AX1–44 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSIS SYSTEM The Electronically Controlled Transaxle has built–in self–diagnostic functions. If the malfunction occurs in the system, the ECM stores the diagnostic trouble code in memory and the O/D OFF (Overdrive OFF) indicator light blinks to inform the driver. The diagnos– tic trouble code stored in memory can be read out by the following procedure.
Page 118 TE1 terminal circuit on page AX1–110. DIAGNOSTIC TROUBLE CODE CHECK BY USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details.
Page 119 ECM TERMINALS STANDARD VALUE ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA break–out–box and TOYOTA hand–held tester to the vehicle. 2. Read the ECM input/output values by following the prompts on the tester screen.
Page 120 AX1–47 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CHECK TERMINAL TT OUTPUT VOLTAGE When a voltmeter is connected to the DLC2, the following items can be checked: 1. Throttle position sensor signal 2. Brake signal 3. Shift position signal 1. VOLTMETER CONNECTION Connect the positive (+) probe of the voltmeter to terminal Tt and the negative (–) probe to terminal E1 of the DLC2.
Page 121 AX1–48 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble. If the problem is that the transaxle does not up–shift, does not down –shift, or the shift point is too high or too low, conduct the following road test to confirm the automatic shift schedule and simulate the problem symptoms.
Page 122 AX1–50 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (c) Check for abnormal noise and vibration. Run at the D position lock–up or O/D gear and check for abnormal noise and vibration. HINT: The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also be due to loss of balance in the torque converter clutch, etc.
Page 123 AX1–51 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (b) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (c) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down– shift.
Page 124 AX1–52 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 4. R POSITION TEST Shift into the R position and while starting at full throttle, check for slipping. CAUTION: Before conducting this rest ensure that the test area is free from personnel and obstructions. 5. P POSITION TEST Stop the vehicle on a gradient (more than 5 _) and after shifting into the P position, release the parking brake.
Page 125 AX1–52 AUTOMATIC TRANSAXLE – TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE SHIFT POINT NORM Mode Shifting point Vehicle speed km/h (mph) Shift position D position 2 position L position PWR Mode Shift position Shifting point Vehicle speed km/h (mph) D position 2 position L position...
Page 126 AX1–53 AUTOMATIC TRANSAXLE – TROUBLESHOOTING LOCK–UP POINT NORM Mode D position Lock–up OFF km/h (mph) Lock–up ON km/h (mph) Throttle valve opening 596 3rd Gear O/D Gear PWR Mode D position Lock–up OFF km/h (mph) km/h (mph) Lock–up ON Throttle valve opening 596 3rd Gear O/D Gear *O/D main switch OFF...
Page 127 AX1–54 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PRELIMINARY CHECK 1. CHECK FLUID LEVEL HINT: Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70–80 C (158–176 F) Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run.
Page 128 AX1–55 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 5. INSPECT AND ADJUST THROTTLE CABLE (a) Check that the throttle valve is fully closed. (b) Check that the inner cable is not slack. (c) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0–1 mm (0–0.04 in.) If the distance is not standard, adjust the cable by the...
Page 129 AX1–56 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 7. INSPECT AND ADJUST PARK/NEUTRAL POSITION SWITCH Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as started above, carry out the following adjust– ment procedure: (a) Loosen the park/neutral position switch bolt and set the shift lever to the N position.
Page 130 AX1–57 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MECHANICAL SYSTEM TESTS STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE: Perform the test at normal operating fluid temperature 50–80 C (122–176 Do not continuously run this test longer than 5 seconds.
Page 131 AX1–58 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem Engine output may be insufficient. Stator one–way clutch is operating properly HINT: (a) Stall speed low in D and R posi- If more than 600 rpm below the specified value, the tions.
Page 132 AX1–59 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the 4/D direct clutch, forward clutch, direct clutch, and first and reverse brake.
Page 133 AX1–60 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION If N1D or N1R time lag are longer than specified: Problem Possible cause Line pressure too low Forward clutch worn NXD time lag is longer O/D one–way clutch not operating properly Line pressure too low Direct clutch worn NXR time lag is longer First and reverse brake worn...
Page 134 AX1–61 AUTOMATIC TRANSAXLE – TROUBLESHOOTING HYDRAULIC TEST MEASURE LINE PRESSURE NOTICE: Perform the test at normal operating fluid temperature 50–80 _C (122–176 _F). The line, pressure test should always be carried out in pairs. One technician should observe the conditions of the wheels or wheel stoppers outside the vehicle while the other is performing the test.
Page 135 AX1–62 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem Throttle cable out of adjustment If the measured values at all positions are higher. Throttle valve defective Regulator valve defective Throttle cable out of adjustment Throttle valve defective Regulator valve defective If the measured values at all positions are lower.
Page 136 AX1–63 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechani– cal problem in the transaxle. 1. DISCONNECT SOLENOID WIRE 2. INSPECT MANUAL DRIVING OPERATION Check that the shift and gear positions correspond with the table below.
Page 137 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Memo...
Page 138 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Memo...
Page 139 AX1–66 AUTOMATIC TRANSAXLE – TROUBLESHOOTING STANDARD VALUE OF ECM TERMINAL ECM Terminals Condition Standard Value Wiring Color Symbols IG OFF IG ON Vehicle driving in 2nd gear position IG OFF G ON Vehicle driving in 2nd gear position IG OFF IG ON Vehicle driving under lock–up position Pattern select SW: PWR...
Page 140 AX1–67 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting.
Page 141 AX1–68 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 1. Electronic Circuit See page Suspect Area Symptom Vehicle does not move in any forward position and reverse position Vehicle does not move in a particular position or positions 1 st No up–shift 2nd¿¿ 3rd 3rd !O/D 0 / D!3rd 3rd !2nd...
Page 142 AX1–69 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 143 AX1–70 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 2. On–Vehicle Repair (*:’94 A140E AUTOMATIC TRANSAXLE Repair Manual) See page Suspect Area Symptom Vehicle does not move in R position Vehicle does not move in any forward position or reverse position No lock–up No lock–up OFF No kick–down No engine braking...
Page 144 AX1–71 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 145 AX1–72 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 3. Off–Vehicle Repair (*:’94 A140E AUTOMATIC TRANSAXLE Repair Manual) See page Suspect Area Symptom Vehicle does not move in any forward position Vehicle does not move in reverse position Vehicle does not move in any forward position and reverse position No lock–up No lock–up OFF Large shock during lock–up...
Page 146 AX1–73 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 147 AX1–74 AUTOMATIC TRANSAXLE – TROUBLESHOOTING LOCATION OF CONNECTORS Location of Connectors in Engine Compartment...
Page 148 AX1–75 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Body Sedan Coupe...
Page 149 AX1–76 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Wagon...
Page 150 AX1–77 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Instrument Panel...
Page 151 AX1–78 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 152 AX1–79 AUTOMATIC TRANSAXLE – TROUBLESHOOTING J/B No–1 J/B No.3...
Page 153 AX1–80 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT INSPECTION Diag. Trouble Code 42 No.1 Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The No. 1 vehicle speed sensor outputs a 4–pulse signal for every revolution of the differential case. After this signal has been converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM.
Page 154 AX1–81 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT DESCRIPTION Fail Safe Function If the vehicle speed sensor fails, shift control takes place so that the throttle opening ratio and RPM are controlled according to the shift control map. DIAGNOSTIC CHART 5 V Fixed Check speedometer circuit.
Page 155 AX1–82 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure voltage between terminal S P D of combination meter connector and body ground. (a) Shift the shift lever to N position. (b) Jack up one of the front wheels. (c) Disconnect the cruise control ECU and PPS connectors.
Page 156 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Memo...
Page 157 AX1–84 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Diag. Trouble Code 62 63 Shift Solenoid Valve No–1 and No.2 Circuit CIRCUIT DESCRIPTION Shifting from 1 st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by the ECM. If an open or short circuit occurs in either of the solenoid valves, the ECM controls the remaining normal solenoid to allow the vehicle to be operated smoothly (Fail safe function).
Page 158 AX1–85 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between .terminals of electronically controlled transaxle solenoid connector and body ground. Check shift solenoid valve No.1 or No.2 in Repair or replace malfunctioned transaxle. part. Check harness and connector between Repair or replace harness or con– electronically controlled transaxle solenoid nector.
Page 159 AX1–86 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECT ION PROCEDURE Measure resistance between terminals of electronically controlled transaxle solenoid connector and body ground. Disconnect electronically controlled transaxle so– lenoid connector. Measure resistance between terminals of elec– tronically controlled transaxle solenoid connector and body ground as shown in the illustration. Resistance: 1, 2–Body ground 11–15 0 Go to step...
Page 160 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Memo...
Page 161 AX1–88 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Diag. Trouble Code 64 Shift Solenoid Valve SL Circuit CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. If a malfunction occurs in this circuit and diagnostic trouble code 64 is stored in memory, the O/D OFF indicator light does not blink.
Page 162 AX1–89 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift solenoid valve SL. (1) Check shift solenoid valve SL connector connection. (2) Measure resistance between shift solenoid valve SL connector terminals and body ground. Resistance: 11–15W Check that shift solenoid valve SL makes opera– tion sound when apply battery voltage shift so–...
Page 163 AX1–90 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Throttle Position Sensor Circuit CIRCUIT DESCRIPTION. The throttle position sensor detects the throttle valve opening angle and sends signals to the ECM. DIAGNOSTIC CHART Proceed to next circuit inspection Throttle position signal check. shown on matrix chart (See page AX1–68).
Page 164 AX1–91 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Throttle position signal check. Turn ignition switch ON (Do not start the engine). Check voltage at terminal TT of the DLC2 while gradually depressing the accelerator pedal from the fully closed position to the fully opened position. Voltage changes from 0 V to 8 V by stages.
Page 165 AX1–92 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in the D position.
Page 166 AX1–93 AUTOMATIC TRANSAXLE – TROUBLESHOOTING WIRING DIAGRAM...
Page 167 AX1–94 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals NSW, 2, L of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminals NSW, 2, L of ECM connector and body ground when the shift lever is put in the following positions. NSW–body 2–body L–body...
Page 168 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Memo...
Page 169 AX1–96 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Stop Light Circuit CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling when the brakes are suddenly applied while driving in lock–up condition. When the brake pedal is operated, this switch sends a signal to the ECM. Then the ECM cancels opera– tion of the lock–up clutch while braking is in progress.
Page 170 AX1–97 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check operation of stop light. Check if the stop light goes on and off normally when the brake pedal is depressed and released . Check and repair stop light circuit (See page BE–50) Check stop light signal.
Page 171 AX1–98 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Pattern Select Switch Circuit The ECM has stored in its memory the gear shift patterns for D position, 2nd position and L position, and also the lock–up pattern for D position. Two types of gear shifting pattern and lock–up pattern are recorded for D position;...
Page 172 AX1–99 AUTOMATIC TRANSAXLE – TROUBLESHOOTING WIRING DIAGRAM...
Page 173 AX1–100 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift pattern switch operation. Check that the shift point changes when the pattern select switch is operated. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check PWR indicator light. Turn IG switch 4N.
Page 174 AX1–101 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check pattern select switch. Disconnect pattern select switch connector. Measure resistance between terminals 3 and6 of pattern select switch connector when the select switch is set to PWR and NORMAL positions. Resistance Pattern 0W (continuity) PW R NORM...
Page 175 AX1–102 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O–D Main Switch & O–D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go off when the switch is pushed in and come on when it is pushed out. In O/D main switch OFF position, the O/D OFF indicator lights up, and the ECM prohibits shifting to overdrive.
Page 176 AX1–103 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check O/D OFF indicator light while engine starting. Proceed to next circuit inspection Check O/D main switch operation. shown on matrix chart (See page AX1–68). Repair or replace harness or connec– Measure voltage between terminal 1 of O/D tor between combination meter and main switch and body ground.
Page 177 AX1–104 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check 0 /D OFF indicator light when engine starting. When starting the engine, check the operating con– dition of the O/D OFF indicator light. O/D OFF indicator lights immediately after the engine is started. Remains ON..
Page 178 AX1–105 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Measure voltage between terminal 1 of O/D main switch connector and body ground. (1) Disconnect O/D main switch connector. (2) Turn IG switch ON. Measure voltage between terminal 1 of O/D main switch harness side connector and body ground. Voltage: 10–14 V Repair or replace harness or connector be–...
Page 179 AX1–106 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check O/D OFF indicator light when you disconnect O/D main switch connector. Turn IG switch ON. Check that the O/D OFF indicator light goes off when you disconnect the O/D main switch con– nector. Replace O/D main switch. Check 0 /D OFF indicator light when you disconnect ECM connector (including OD2 terminal).
Page 180 AX1–107 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check indicator lights on combination meter other than O/D OFF indicator light. Turn IG switch ON. Check the following indicator lights on combination meter: Check Engine Light Low Oil Pressure Warning Light ABS Warning Light etc. Above indicator lights light up.
Page 181 AX1–108 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O–D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving with cruise control activated, in order to minimize gear shifting and provide smooth cruising uphill, overdrive may be prohibited temporarily in some conditions. The cruise control ECU sends OD cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are disconnected.
Page 182 AX1–109 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal OD1 of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal 01 31 of ECM connector and body ground. Voltage: 10–14 V Proceed to next circuit inspection shown on matrix chart (See page AX1–68).
Page 183 AX1–110 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TE1 Terminal Circuit CIRCUIT DESCRIPTION The ECM displays diagnostic trouble codes using the O/D OFF indicator light when terminals TE1 and E1 of the DLC2 or DLC1 are connected. DIAGNOSTIC CHART Proceed to next circuit inspection Check voltage between terminals TE1 and E1 shown on matrix chart (See page of DLC2 or DLC1.
Page 184 AX1–111 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals TE, and E, of DLCZ or DLC1. Measure voltage between terminals TE, and E, of DLC2 or D LC1. Voltage: 4–6 V Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check harness and connector between ECM and DLC2, DLC1 and body ground (See page IN–31...
Page 185 AX1–112 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Terminal Circuit CIRCUIT DESCRIPTION Checks of ECM input and output signals related to the throttle position sensor, brakes, shift position and other circuits can be performed by measuring the voltages at terminal T, of DLC1. DIAGNOSTIC CHART Check harness and connector between ECM Repair or replace harness or con–...
Page 186 AX1–113 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Engine idling Line pressure (whell locked) D position R position AT stall D position R position Engine stall revolution Time lag Engine idle speed (Cooling fan and A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Limit Torque converter runout...
Page 187 AX1–114 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened Engine rear mounting bracket x Front suspention member Engine rear mounting bracket x Front suspention member LH transaxle mounting Transaxle x Engine 12 mm bolt Transaxle x Engine 10 mm bolt Torque converter clutch x Drive plate Valve body x Transaxle case Oil strainer...
Page 188 AX2–1 AUTOMATIC TRANSAXLE – A541E AUTOMATIC TRANSAXLE...
Page 189 AX2–2 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION GENERAL DESCRIPTION The ’94 model years A541 E automatic transaxle is a revised version of the previous model year’s A540E automatic transaxle. The following changes have been made to match the brand new 1 MZ –FE engine: Adoption of an Electronically Controlled Transaxle with an intelligent control system.
Page 190 AX2–3 AUTOMATIC TRANSAXLE – DESCRIPTION GENERAL SPECIFICATIONS Type of Transaxle Type of Engine Torque Converter Clutch Stall Torque Ratio Torque Converter Clutch Lock–up Mechanism Gear Ratio 1 st Gear 2nd Gear 3rd Gear O/D Gear Reverse Gear Transaxle Number of Discs and Plates 0/D Direct Clutch (Co) Forward Clutch (C,) .
Page 191 AX2–4 AUTOMATIC TRANSAXLE – OPERATION OPERATION 1. MECHANICAL OPERATION p ..Operating Shift lever Gear Position position Parking Reverse Neutral 1 st 1 st *3rd 1 St ‘2nd *Down–shift only – no up–shift...
Page 192 AX2–5 AUTOMATIC TRANSAXLE – OPERATION 2. FUNCTION OF COMPONENTS COMPONENT FUNCTION Connects input shaft and front planetary ring gear Forward Clutch Connects input shaft and front & rear planetary sun gear Direct Clutch Prevents front & rear planetary sun gear from turning either clockwise or 2nd Coast Brake counterclockwi Prevents outer race o I from turning either clockwise or counterclockwise, thus...
Page 193 AX2–6 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit.
Page 194 AX2–7 AUTOMATIC TRANSAXLE – OPERATION 3. HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes as well as the fluid passagas which connect all of these components.
Page 195 AX2–8 AUTOMATIC TRANSAXLE – OPERATION 4. ELECTRONIC CONTROL SYSTEM GENERAL The electronic control system for the A541 E automatic transaxte provides extremely precise control of the gear shift timing and lock–up timing in response to driving conditions as sensed by various sensors located throughout the vehicle and in response to the engine’s running condition.
Page 196 AX2–9 AUTOMATIC TRANSAXLE – OPERATION ARRANGEMENT OF COMPONENTS...
Page 197 Cruise Control ECU speed drops below the auto drive set speed parameter. By connecting the OBD II scan tool or TOYOTA hand– Data Link Connector 3 held tester the transaxle control data can be read.
Page 198 AX2–11 AUTOMATIC TRANSAXLE – OPERATION SYSTEM DIAGRAM...
Page 199 09316–60010 Transmission & Transfer Bearing differential case. Reptacer Install right sid, gear shaft oil (09316–00010) Replacer Pipe seal. 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Tool (09351–32020) Stator Stopper Line pressure 09992–00094 Automatic Transmission Oil Pressure Gauge Set...
Page 200 AX2–13 AUTOMATIC TRANSAXLE – PREPARATION RECOMMENDED TOOLS 09031–00030 Pin Pin diameter 3 mm(0.12 in.) Punch 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Straight edge Check torque converter clutch installation. Vernier calipers Check torque converter clutch installation. Dial indicator or dial indicator with magnetic base Measure drive plate runout.
Page 201 AX2–14 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR ON–VEHICLE REPAIR CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. VEHICLE SPEED SENSOR REPLACEMENT (w/Speedometer Driven Gear) 1.
Page 202 AX2–15 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR DIRECT CLUTCH SPEED SENSOR REPLACEMENT 1. DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR 2. REMOVE DIRECT CLUTCH SPEED SENSOR (a) Remove the bolt and direct clutch speed sensor. (b) Remove the 0 –ring from direct clutch speed sensor. 3.
Page 203 AX2–16 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR PARK/NEUTRAL POSITION SWITCH REPLACEMENT 1. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 2. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the clip from the shift control cable. (b) Remove the nut and control cable. (c) Remove the transaxle control shaft lever. (d) Remove the park/neutral position switch.
Page 204 AX2–17 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR (b) Adjust the park/neutral position switch. (See page AX2–69) (c) Install the transaxle control shaft lever. (d) Install the control cable and nut. (e) Install the clip to the shift control cable. 5. CONNECT PARK/ NEUTRAL POSITION SWITCH CONNECTOR 6.
Page 205 AX2–18 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY REMOVAL 1. CLEAN TRANSAXLE EXTERIOR To help prevent contamination, clean the exterior of the transaxle. 2. DRAIN TRANSAXLE FLUID Using SST, remove the drain plug and the fluid into suitable container. SST 09043 – 38100 3.
Page 206 AX2–19 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 7. DISCONNECT SOLENOID CONNECTORS 8. REMOVE TRANSFER LUBRICATION APPLY TUBE (a) Remove the 2 bolts and detent spring. (b) Remove the tube set bolts. (c) Pry up the tube with a screwdriver and remove the tube.
Page 207 AX2–20 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 10. REMOVE B3 APPLY TUBE (a) Remove the tube retainer. (b) Pry up the tube with a screwdriver and remove the tube. 11. REMOVE VALVE BODY (a) Remove the 11 bolts. (b) Disconnect the throttle cable from cam and remove the valve body.
Page 208 AX2–21 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY INSTALLATION 1. INSTALL NEW SECOND BRAKE APPLY GASKET 2. INSTALL VALVE BODY (a) While holding the cam down with your hand, slip the cable end into the slot. (b) Bring valve body into place. NOTICE: Be careful not to entangle the solenoid wire.
Page 209 AX2–22 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 5. INSTALL TRANSFER LUBRICATION APPLY TUBE AND DETENT SPRING (a) Using a plastic hammer, install the tube into the posi– tion indicated in the illustration. NOTICE: Be careful not to bend or damage the tube. (b) Install the bolt.
Page 210 AX2–23 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 8. INSTALL OIL STRAINER AND APPLY TUBE BRACK– Install the oil strainer. Torque: 11 N–m (110 kgf–cm, 8 ft–Ibf) Install the tube bracket. Torque: 10 N–m (100 kgf–cm, 7 ft–Ibf) HINT: Each bolt length (mm, in.) is indicated in the illustration.
Page 211 AX2–24 AUTOMATIC TRANSAXLE – ON –VEHICLE REPAIR THROTTLE CABLE REMOVAL 1. DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. 2. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX2–61) 3. REMOVE VALVE BODY (See page AX2–18) 4. REMOVE THROTTLE CABLE (a) Remove the bolt and retaining plate.
Page 212 AX2–25 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 4. CONNECT THROTTLE CABLE TO ENGINE 5. ADJUST THROTTLE CABLE (See page AX2–69) 6. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX2–16) 7. TEST DRIVE VEHICLE...
Page 213 AX2–26 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR SIDE GEAR SHAFT OIL SEAL REPLACEMENT 1. REMOVE BOTH DRIVE SHAFTS (See page SA–22) 2. REMOVE BOTH SIDE GEAR SHAFT OIL SEALS Using SST, pull out the oil seal. SST 09308–00010 3. INSTALL LEFT SIDE GEAR SHAFT OIL SEAL (a) Using SST, drive in a new oil seal.
Page 214 AX2–27 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION Remove and install the parts as shown.
Page 215 AX2–28 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL 1. DISCONNECT AND REMOVE BATTERY 2. REMOVE AIR CLEANER ASSEMBLY 3. REMOVE THROTTLE CABLE FROM ENGINE 4. REMOVE CRUISE CONTROL ACTUATOR (a) Remove the cruise control actuator cover. (b) Disconnect the connector. (c) Remove the 3 bolts and cruise control actuator with bracket.
Page 216 AX2–29 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 8. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 9. DISCONNECT SOLENOID CONNECTOR 10. DISCONNECT SHIFT CONTROL CABLE (a) Remove the clip from the shift control cable. (b) Remove the unit. 11. REMOVE EARTH CABLES 12.
Page 217 AX2–30 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 13. REMOVE 2 FRONT SIDE TRANSAXLE MOUNTING BOLTS 14. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS 15. REMOVE 2 OIL COOLER CLAMPING BOLTS FROM FRONT FRAME ASSEMBLY 16. REMOVE STARTER (a) Disconnect the connector and remove the nut. (b) Remove the 2 bolts and the starter.
Page 218 AX2–31 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 18. INSTALL ENGINE SUPPORT FIXTURE 19. TIE STEERING GEAR HOUSING TO ENGINE SUP– PORT FIXTURE BY CODE OR EQUIVALENT 20. RAISE AND SUITABLY SUPPORT VEHICLE 21. REMOVE FRONT WHEEL 22. REMOVE EXHAUST FRONT PIPE (a) Remove the 2 bolts and exhaust front pipe clamp.
Page 219 AX2–32 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO.2 26. REMOVE ENGINE UNDER FRONT COVER NO.1 AND NO.2 27. REMOVE DRIVE SHAFT (See page SA–22) 28. REMOVE FRONT SIDE ENGINE MOUNTING NUT 29.
Page 220 AX2–33 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Remove 2 bolts and nuts from the steering gear housing. (c) Remove the steering gear housing. 32. REMOVE FRONT FRAME ASSEMBLY (a) Hold the front frame assembly with a jack. (b) Remove 2 set screws from the right and left fender liners.
Page 221 AX2–34 AUTOMATIC TRANSAXLE – r ASSEMBLY REMOVAL AND INSTALLATION (b) Turn the crankshaft to gain access to each bolt. (c) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. 35. REMOVE EXHAUST MANIFOLD PLATE 36. REMOVE TRANSAXLE TO ENGINE BOLTS 37.
Page 222 AX2–35 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION 1. INSPECT ONE–WAY CLUTCH (a) Install SST into the inner race of the one–way clutch. SST 09350–32014 (09351–32020) (b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch.
Page 223 AX2–36 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. If runout exceeds 0.30 mm (0.0118 in.), try to correct by reorienting the installation of the converter.
Page 224 AX2–37 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 3. ALIGN TRANSAXLE AT INSTALLATION POSITION (a) Align the 2 knock pins on the block with the converter housing. (b) Temporarily install the bolt. 4. INSTALL TRANSAXLE TO ENGINE BOLTS Install the transaxle to engine bolts. 12 mm head bolt Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 10 mm head bolt...
Page 225 AX2–38 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 7. INSTALL FRONT FRAME ASSEMBLY (a) Hold the front frame assembly. (b) Install the6 bolts and 4 nuts. (c) Torque the bolts and nuts. 19 mm head bolt Torque: 1$1 N–m (1,850 kgf–cm, 134 ft–lbf) 12 mm head bolt Torque: 32 N–m (330 kgf–cm, 24 ft–lbf) Torque: 36 N–m (370 kgf–cm, 27 ft–lbf)
Page 226 AX2–39 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 9. INSTALL FOUR LEFT SIDE TRANSAXLE MOUNT– ING BOLTS Torque: 52 N–m (530 kgf–cm. 38 ft–lbf) 10. INSTALL REAR SIDE MOUNTING BOLTS AND NUTS (a) Install and torque the 2 bolts and nuts. Torque:66 N–m (670 kgf–cm, 48 ft–lbf) (b) Install 2 hole plugs.
Page 227 AX2–40 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 18. INSTALL EXHAUST FRONT PIPE (a) Install a new gasket. (b) Install the exhaust front pipe. (c) Install and torque 2 bolts and new nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (d) Install the exhaust front pipe support and 2 bolts.
Page 228 AX2–41 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 21. INSTALL 4 UPPER TRANSAXLE TO ENGINE BOLTS Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 22. INSTALL STARTER (a) Install the starter with the 2 bolts. (b) Torque the 2 bolts. Torque: 38 N–m (400 kgf–cm, 29 ft–lbf) (c) Connect the connector and install the nut.
Page 229 AX2–42 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. CONNECT OIL COOLER HOSE 27. INSTALL EARTH CABLES 28. CONNECT SHIFT CONTROL CABLE (a) Install the clip from the shaft control cable. (b) Install and torque the nut. (c) Adjust the shift control cable. (See page AX2–69) 29.
Page 230 AX2–43 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. CONNECT DIRECT CLUTCH SPEED SENSOR CON– NECTOR 32. CONNECT VEHICLE SPEED SENSOR CONNECTOR 33. INSTALL GROUND TERMINAL 34. INSTALL CRUISE CONTROL ACTUATOR (a) Install the cruise control actuator with bracket the 3 bolts.
Page 231 AX2–44 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 38. FILL TRANSAXLE WITH ATF AND CHECK FLUID LEVEL (See page AX2–68) NOTICE: Do not overfill. Fluid type: ATF DEXRON ll 39. INSPECT FRONT WHEEL ALIGNMENT (See page SA–4) 40. PERFORM ROAD TEST Check for abnormal noise and smooth shifting.
Page 232 AX2–45 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM COMPONENT PARTS LOCATION WIRING DIAGRAM...
Page 233 AX2–46 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM ELECTRIC CONTROL COMPONENTS INSPECTION 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each termi– nal. HINT: Do not disconnect the computer connector. Connector Terminal Measuring condition Voltage (V) Ignition switch ACC position Ignition switch ON position Depress brake pedal...
Page 234 AX2–47 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM 3. INSPECT KEY INTERLOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5–16–60 (c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid.
Page 235 AX2–48 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM –Memo–...
Page 236 AX2–49 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TROUBLESHOOTING...
Page 237 (4) CLEAR DIAGNOSTIC TROUBLE CODE AND FREEZED FRAME DATA Use the OBDII scan tool or TOYOTA hand – held tester to erase the diagnostic trouble codes and freezed frame data.
Page 238 AX2–51 AUTOMATIC TRANSAXLE – TROUBLESHOOTING completed. If troubleshooting is attempted only by following the malfunction code stored in the memory is output, errors could be made in the diagnosis. DIAGNOSTIC TROUBLE CODE CHART If a trouble code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code.
Page 239 Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA brake–out–box. Connect the OBD II Scan Tool or TOYOTA Hand–Held Tester to DLC3 If your display shows “UNABLE TO CONNECT TO VEHICLE” when you hvae connected the scan tool/TOYOTA hand–held tester, inspect DLC3 P.AX2–57...
Page 240 AX2–53 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK SHEET Inspector’s Electronically Controlled Name Transaxle Check Sheet Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Odometer Reading Brouht In Miles...
Page 241 To check the diagnostic trouble codes, connect the OBDII scan tool or TOYOTA hand–held tester to Data Link Connector 3 on the vehicle. The OBD ll scan tool or TOYOTA hand–held tester also enables you to erase the diagnostic trouble codes and check freezed frame data and various forms of engine data.
Page 242 1. Prepare the OBDII scan tool (complying with SAE J 1978) or TOYOTA hand–held tester. 2. Connect the OBDll scan tool or TOYOTA hand–held tester to data link connector 3 in the fuse box at the lower left of the instrument panel.
Page 243 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 4. Use the OBD n scan tool or TOYOTA hand–held tester to check the diagnostic trouble codes and free– zed frame data. Note them down. (For operating in– structions, see the OBD n scan tool’s instruction book.)
Page 244 HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD ll scan tool or TOYOTA hand–held tester to DLC 3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side.
Page 245 The following actions will erase the diagnostic trouble codes and freezed frame data. 1. Operating the OBD ll scan tool (complying with SAE J 1978) or TOYOTA hand–held tester to erase the codes. (See the OBDII scan tool’s instruction book for operating instructions.)
Page 246 AUTOMATIC TRANSAXLE – TROUBLESHOOTING NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice – versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the diagnostic trou–...
Page 247 AX2–60 AUTOMATIC TRANSAXLE – TROUBLESHOOTING VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions for looseness or damage and check if the terminals are secured in the lock portion.
Page 248 AX2–61 AUTOMATIC TRANSAXLE – TROUBLESHOOTING –MEMO–...
Page 249 AX2–62 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART If a diagnostic trouble code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the page given. Detection Item Diagnostic Trouble Code Detecting Condition DTC No.
Page 250 AX2–63 AUTOMATIC TRANSAXLE – TROUBLESHOOTING –...MIL does not light up ...MIL lights up ...MIL lights up, O/D OFF indicator light blinks See page Trouble Area Memory Same as for DTC No. P0500. AX2–92 Shift solenoid valve No.1 is stuck open or closed AX2–96 Valve body is blocked up or stuck.
Page 251 AX2–64 AUTOMATIC TRANSAXLE – TROUBLESHOOTING ROAD TEST NOTICE: Perform the test at normal ATF operating tem– perature 50–80 C (122–176 1. D POSITION TEST (NORM AND PWR PATTERN) Shift into the D position and fully depress the acceler– ator pedal and check the following points: (a) Check up–shift operation.1 2, 2 3 and 3 O/D up–shift takes place, at the shift point shown in the automatic shift schedule.
Page 252 AX2–65 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (d) Check kick–down operation While running in the D position, 2nd, 3rd and 0/D gears, check to see that the possible kick–down vehicle speed limits for 2!1, 3!2 and 0/D!3 kick–downs conform to those indicated on the auto– matic shift schedule.
Page 253 AX2–66 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 3. L POSITION TEST Shift into the 2 position and fully depress the acceler– ator pedal and check the following points: (a) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear.
Page 254 AX2–67 AUTOMATIC TRANSAXLE – TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE SHIFT POINT Vehicle speed km/h (mph) Shifting point Shift position Throttle valve fully opened D position Throttle valve fully closed Throttle valve fully opened 2 position Throttle valve fully opened L position LOCK–UP POINT D position km/h (mph) Lock–up ON...
Page 255 AX2–68 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PRELIMINARY CHECK 1. CHECK FLUID LEVEL HINT: Drive the vehicle so that the engine and transmis– sion are at normal operating temperature. Fluid temp. : 70–80 C (158–176 F) Only use the COOL position on the dipstick as a rough reference when the fluid is replaced or the engine does not run.
Page 256 AX2–69 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 5. INSPECT AND ADJUST THROTTLE CABLE (a) Check that the accelerator pedal is fully released. (b) Check that the inner cable is not slack. (c) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0–1 mm (0–0.04 In.) If the distance is not standard, adjust the cable by the...
Page 257 AX2–70 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) For continuity inspection of the park/neutral position switch, see page AX–116. 8. INSPECT IDLE SPEED Idle speed: 650–750 RPM (In N position and air conditioner OFF)
Page 258 AX2–71 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MECHANICAL SYSTEM TESTS STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE: Perform the test at normal operating fluid temperature 50–80 _C (122–176_F). Do not continuously run this test longer than 5 seconds.
Page 259 AX2–72 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem Engine output may be insufficient. Stator one–way clutch is operating properly (a) Stall speed low in D and R positions. HINT: If more than 600 RPM below the specified value, the torque converter could be faulty.
Page 260 AX2–73 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the 0/D direct clutch, forward clutch, direct clutch, and first and reverse brake.
Page 261 AX2–74 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION If N D or N R time lag are longer than specified: Possible cause Problem Line pressure too low N D time lag is longer Forward clutch worn 0/D one–way clutch not operating properly Line pressure too low Direct clutch worn N R time lag is longer...
Page 262 AX2–75 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MEASURE LINE PRESSURE NOTICE: Perform the test at normal operating fluid temperature 50–80 C (122–176 The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. Be careful to prevent the oil pressure gauge hose from interfering with the exhaust pipe.
Page 263 AX2–76 AUTOMATIC TRANSAXLE – TROUBLESHOOTING SPECIFIED LINE PRESSURE Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling Stall If the measured pressures are not up to specified values, recheck the throttle cable adjustment and retest. EVALUATION Problem Possible cause Throttle cable out of adjustment If the measured values at all positions are higher.
Page 264 AX2–77 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechani– cal problem in the transaxle. 1. DISCONNECT SOLENOID WIRE 2. INSPECT MANUAL DRIVING OPERATION Check that the shift and gear positions correspond with the table below.
Page 265 AX2–78 AUTOMATIC TRANSAXLE – TROUBLESHOOTING STANDARD VALUE OF ECM TERMINAL ECM Terminals Connector,Terminal No. Symbols Condition Standard Value Wiring Color 1. Disconnect cruise control connector. 2. Turn ignition switch ON. Standing still Turn one front wheel slowly IG OFF IG ON 1 st or 2nd gear 3rd or O/D gear IG OFF...
Page 266 AX2–79 AUTOMATIC TRANSAXLE – TROUBLESHOOTING IG switch ON Shift lever L position Shift lever other than L position 1G switch ON Shift lever 2 position Shift lever other than 2 position IG switch ON Shift lever R position Shift lever other than R position IG switch ON Shift lever P or N position Shift lever other than P and N position...
Page 267 AX2–80 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting.
Page 268 AX2–81 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 1. Electronic Circuit See Page Suspect Area Symptom Vehicle does not move in any forward range and reverse range Vehicle does not move in particular range or ranges 1st!2nd No up–shift 2nd!3rd 3rd!O/D O/D!3rd No down–shift 3rd!2nd 2nd!1st...
Page 269 AX2–82 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 2. On–Vehicle Repair (* : A541 E AUTOMATIC TRANSAXLE Repair Manual) See page Suspect Area Symptom Vehicle does not move in R position Vehicle does not move in any forward position or reverse position No lock–up No lock–up OFF No kick–down...
Page 270 AX2–83 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 271 AX2–84 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 3. Off–Vehicle Repair ( * : A541 E AUTOMATIC TRANSAXLE Repair Manual) See page Suspect Area Symptom Vehicle does not move in any forward position Vehicle does not move in reverse position Vehicle does not move in any forward position and reverse position No lock–up No lock–up OFF Large shock during lock–up...
Page 272 AX2–85 AUTOMATIC TRANSAXLE – TROUBLESHOOTING...
Page 273 AX2–86 AUTOMATIC TRANSAXLE – TROUBLESHOOTING LOCATION OF CONNECTORS Location of Connectors in Engine Compartment Data Link Connector 1 Electronic Controlled Junction Connector O/D Direct Clutch Transaxle Connector Speed Sensor EF 1 Park/neutral Position...
Page 274 AX2–87 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Body Sedan Light Failure Sensor...
Page 275 AX2–88 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Instrument Panel Combination Meter Cruise Control ECU Combination Meter Electronic Controlled Transaxle Engine Control Module Engine Control Mod- Pattern Select Switch...
Page 276 AX2–89 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Engine Control Module Engine Control Module Ignition SW and Unlock Warning SW Stop Light Switch Noise Filter Noise Filter O/D Main SW Junction Connector Junction Connector Junction Connector...
Page 277 AX2–90 AUTOMATIC TRANSAXLE – TROUBLESHOOTING J/B No.1...
Page 278 AX2–91 AUTOMATIC TRANSAXLE – TROUBLESHOOTING J/B No.2 J/B No–3...
Page 279 AX2–92 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT INSPECTION DTC P0720 Output Speed Sensor Circuit Malfunction (For Electronically Controlled Transaxle) CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the transaxle differential. After this signal has been converted into a more precise rectangular wave form by the wave form shaping circuit inside the combination meter, it is then transmitted to the ECM.
Page 280 AX2–93 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure voltage between terminals SP 1 Go to step and E, of ECM connector. Measure voltage between terminal 14 of Check for open circuit between combination meter center connector and ECM and combination meter. body ground.
Page 281 AX2–94 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure voltage between terminals SP 1 and E 1 of ECM connector. 1. Disconnect cruise control ECU connector. 2. Turn IG switch ON. Measure voltage between terminals SP1 and E1 of ECM connector. Voltage: 5 V Go to step Measure voltage between terminal 14 of combination meter center...
Page 282 AX2–95 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check continuity between terminal SP1 of ECM connector and body ground. Disconnect connector from ECU. Check continuity between terminal SP1 of ECM connector and body ground. No continuity Check for short circuit between ECM, cruise control ECU and combination meter.
Page 283 AX2–96 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0750 Shift Solenoid A Malfunction Shift Solenoid No.1 DTC P0755 Shift Solenoid B Malfunction Shift Solenoid No.2 SYSTEM DESCRIPTION The ECM uses signals from the NC2 revolution sensor and vehicle speed sensor to detect the actual gear position(1 st, 2nd, 3rd or O/D gear).
Page 284 AX2–97 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check solenoid valve No. 1 or No.2 operation. 1. Remove the oil pan. 2. Remove the No. 1 or No. 2 solenoid valve. 1. Applying 490 kPa (5 kg/flcm2, 71 psi) of com– pressed air, check that the solenoid valves do not leak the air.
Page 285 AX2–98 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0753 Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No. 7) DTC P0758 Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No. 2) CIRCUIT DESCRIPTION The ECM controls the shifting from 1st to O/D in combination with ON and OFF of the shift solenoid valves No.
Page 286 AX2–99 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between S 1 or S2 ter– Replace ECM. minal of ECM connector and body ground. Check harness and connector between Repair or replace harness or con– ECM and automatic transaxle solenoid connector. nector.
Page 287 AX2–100 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure resistance between S 1 or S2 terminals of ECM connector and body ground. Measure resistance between S 1 or S2 terminals of ECM connector and body ground. Resistance: 10–16 9 Replace ECM. Check harness and connector between ECM and automatic transaxle solenoid connector.
Page 288 AX2–101 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check No. 1 or No.2 solenoid valves. 1. Jack up the vehicle. 2. Remove oil pan. 3. Disconnect solenoid connector. 4. Remove No. 1 or No. 2 solenoid valve. Measure resistance between solenoid connector and body ground. Resistance: 10–16 Ω...
Page 289 AX2–102 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION The ECM uses the signals from the NC2 revolution sensor and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the ECM compares the engagement condition of the lock–up clutch with the lock–up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body and...
Page 290 AX2–103 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check solenoid valve SL operation. Remove SL solenoid valve from valve body. 1. Applying 490 kPa (5 kgf/cm2, 71 psi)of com– pressed air, check that the solenoid valves do not leak air. 2. When battery voltage is supplied to the solenoid valves, check that the solenoid valves open.
Page 291 AX2–104 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pres- sure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. Fail Safe Function If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF.
Page 292 AX2–105 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Replace ECM. Measure resistance between terminals SL and E, of ECM connector. Repair or replace harness or con– Check harness and connector between nector between ECM and automatic ECM and automatic transaxle. transaxle solenoid connector. Check SL solenoid valve.
Page 293 AX2–106 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure resistance between terminals SL of ECM connector and body ground. Disconnect connector from the ECM. Measure resistance between terminals SL and E, of the ECM. Resistance: 8–100,000 Replace ECM. Check harness and connector between ECM and automatic transaxle. 1.
Page 294 AX2–107 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check SL solenoid valve. 1. Jack–up the vehicle. 2. Remove oil pan. 3. Disconnect SL solenoid valve connector. 4. Remove SL solenoid valve. Measure resistance between SL solenoid connec– tor terminal and its body ground. Resistance: 10–16 9 Check SL solenoid valve operation noise when applying battery voltage to the solenoid connec–...
Page 295 AX2–108 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC Pl705 “NC2” Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the direct clutch drum. By comparing the direct clutch speed signal and the vehicle speed sensor signal, the ECM detects the shift timing of the gears and ap–...
Page 296 AX2–109 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check resistance between terminals NC2+ Replace ECM. and NC2–of ECM connector. Replace direct clutch speed sen– Check direct clutch speed sensor. sor. Check and repair harness and connector between ECM and O/D direct clutch speed sensor. WIRING DIAGRAM...
Page 297 AX2–110 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check resistance between terminals NC2 and NC2 of ECM connector. – Check resistance between terminals NC2+ and NC2–of ECM connector. Resistance: 560–680 9 Replace ECM. Check direct clutch speed sensor. Remove direct clutch speed sensor. (See page AX2–1 Measure resistance between terminals 1 and 2 of...
Page 298 AX2–111 AUTOMATIC TRANSAXLE – TROUBLESHOOTING –MEMO–...
Page 299 AX2–112 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P1765 Shift Solenoid Valve SLN Circuit (For Accumulator Back Pressure Modulation) CIRCUIT DESCRIPTION The shift solenoid valve SLN controls the hydraulic pressure acting on the accumulator control valve when gears are shifted and per– forms smooth gear shifting.
Page 300 AX2–113 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check solenoid valve SLN. Replace solenoid valve SLN. Check harness and connector between bat– Repair or replace harness or con– tery and solenoid valve SLN, solenoid valve SLN nector. IN–31 and ECM (See page Replace ECM.
Page 301 AX2–114 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift solenoid valve SLN. Check solenoid resistance 1. Jack up the vehicle. 2. Remove oil pan. 3. Disconnect the connector. Measure resistance between terminals 1 and 2 of solenoid connector. Resistance: 5.1–5.5 9 Check solenoid operation Connect positive lead with an 8–10 w bulb to...
Page 302 AX2–115 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between battery and shift solenoid valve IN–31 SLN, shift solenoid valve SLN and ECM (See page Repair or replace harness or connector. Replace ECM.
Page 303 AX2–116 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P1780 Park Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to ECM. The ECM receives signals (R, NSW, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in the D posi–...
Page 304 AX2–117 AUTOMATIC TRANSAXLE – TROUBLESHOOTING WIRING DIAGRAM...
Page 305 AX2–118 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal R, NSW, 2, L of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminals R, NSW, 2, L of ECM connector and body ground when the shift lever is shifted to the following positions.
Page 306 AX2–119 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between ECM and PNP switch, PNP switch and battery. Repair or replace harness and connector. Check and replace ECM.
Page 307 AX2–120 AUTOMATIC TRANSAXLE – TROUBLESHOOTING OD Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruis– ing, overdrive may be prohibited temporarily in some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shif– ting until these signals are discontinued.
Page 308 AX2–121 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal OD 1 of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal OD 1 of ECM connector and body ground. Voltage: 4–6 V Proceed to next circuit inspection shown on matrix chart (See page AX2–81).
Page 309 O/D main switch OFF position, the O/D OFF indicator lights up, and the ECM prohibits shifting to overdrive. The ECM also causes the O/D OFF indicator light to blink when a malfunction is detected. In this case, con– necting the OBD II scan tool or TOYOTA hand–held tester to the DLC3 can display the diagnostic trouble code.
Page 310 AX2–123 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O/D OFF indicator light remains ON Check O/D main switch. Replace O/D main switch. Check harness and connector between Repair or replace harness or con– O/D off indicator light and O/D main nector. switch, O/D off indicator light and ECM. Check and replace ECM.
Page 311 AX2–124 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check operation of O/D Main Switch. 1. Turn ignition switch ON 2. Check ”O/D OFF” light when O/D main switch is pushed in to ON. “O/D OFF” light goes off. 3. Check ”O/D OFF” light when O/D main switch is pushed again, to OFF.
Page 312 AX2–125 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between O/D off indicator light and ECM. Repair or replace harness or connector. Check and replace ECM. Check O/D Main Switch. 1. Disconnect O/D main switch connector. 2. Measure resistance between terminals 1 and 3 of O/D main switch connector.
Page 313 AX2–126 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Pattern Select Switch Circuit CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, and L position and the lockup patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position switch and other various sensors the ECM switches the solenoid valves ON and OFF, thereby controlling the transaxle gear change and the lockup clutch operation.
Page 314 AX2–127 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal P of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal P of ECM con– nector and body ground when the pattern select switch is set to the PWR (POWER) position and NORM (NORMAL) position.
Page 315 DIAGNOSTIC CHART Check operation of stop light. Check and repair stop light circuit. Proceed to next circuit inspection Connect the TOYOTA hand–held tester and shown on matrix chart (See page check STP signal. AX2–8 1 ).
Page 316 AX2–129 AUTOMATIC TRANSAXLE – TROUBLESHOOTING WIRING DIAGRAM...
Page 317 Check if the stop lights go on and off normally when the brake pedal is operated and released. Check and repair stop light circuit. Connect TOYOTA hand–held tester and check STP signal. 1. Remove the fuse cover on the instrument panel.
Page 318 AX2–131 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Engine idling Line pressure (whell locked) D position R position AT stall D position R position Engine stall revolution Time lag N position–D position N position–R position Engine idle speed (Cooling fan and A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Torque converter clutch runout...
Page 319 AX2–132 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened kgf–cm ft–lbf N–m Engine front mounting bracket x Front suspention menber Engine rear mounting bracket x Front suspention menber LH transaxle mounting Transaxle x Engine 12mm bolt Transaxle x Engine 10mm bolt Torque converter clutch x Drive–plate Valve body x Transaxle case...
Page 320 BE–1 BODY ELECTRICAL SYSTEM – BODY ELECTRICAL SYSTEM...
Page 321 BE–2 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION GENERAL INFORMATION WIRING COLOR CODE Wire colors are indicated by an alphabetical code. B=Black L=Blue R=Red BR=Brown LG=Light Green V =Violet G=Green O=Orange W=White GR=Gray P=Pink Y =Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe.
Page 322 BE–3 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left.
Page 323 BE–4 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION FUSE REPLACEMENT HINT: If replacing the fuse be sure to replace it with a fuse with an equal amperage rating. NOTICE: Turn off all electrical components and the ignition switch before replacing a fuse or fusible link. Do not exceed the fuse or fusible link amperage rating.
Page 324 BE–5 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: A–Ignition SW on B–Ignition SW and SW 1 on C–Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative (–) lead to a good ground point or negative (–) battery terminal and the positive (+) lead to the connector or compo–...
Page 325 BE–6 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION (c) Use a volt/ohmmeter with high impedance (10 k/V minimum) for troubleshooting of the electrical circuit. BULB CHECKING (a) Remove the bulb. (b) There should be continuity between the respective terminals of the bulb together with a certain amount of resistance.
Page 326 BE–7 BODY ELECTRICAL SYSTEM – PRECAUTION PRECAUTION Take care to observe the following precautions when performing inspections or remOval and replacement of body electrical related parts. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst or scatter if scratched or dropped.
Page 327 PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09213–31021 Crankshaft Pulley Puller For removing steering wheel RECOMMENDED TOOLS 09062–00050 TOYOTA Electrical Tester Set 09041–00030 Torx Driver T30 For removing and installing steering wheel pad 09042–00010 Torx Socket T30 For removing and installing...
Page 328 BE–9 BODY ELECTRICAL SYSTEM – POWER SOURCE POWER SOURCE PARTS LOCATION...
Page 329 BE–10 BODY ELECTRICAL SYSTEM – POWER SOURCE Junction Block No.2 MEDIUM CURRENT FUSES 1. MAIN 40A 2. RDI 30A 3. CDS 30A FUSES 4. – 5. EFI 15A 6. HORN 10A 7. OBD, TRAC 7.5A 7.5A 8. HAZ 1 OA 9.
Page 330 BE–11 BODY ELECTRICAL SYSTEM – POWER SOURCE Junction Block No. 1 (Front Side) RELAYS A. Power Main Relay B. Taillight Control Relay C. Defogger Relay Relay Block No–1 FUSE 1. ST Fuse 10A RELAY A. Turn Signal Flasher Relay Block No.4 FUSES Medium Current Fuse 1.
Page 331 BE–12 BODY ELECTRICAL SYSTEM – POWER SOURCE Relay Block No.5 5S–FE Engine FUSES 1. HEAD RH (Lo) 15A (CANADA) 2. HEAD LH (Lo) 15A (CANADA) RELAYS A. Daytime Running Light Relay No.2 (CANADA) B. Magnet Clutch Relay C. FAN No.2 Relay D.
Page 332 BE–13 BODY ELECTRICAL SYSTEM – POWER SOURCE WIRING DIAGRAM...
Page 333 BE–14 BODY ELECTRICAL SYSTEM – IGNITION SWITCH IGNITION SWITCH PARTS LOCATION IGNITION SWITCH INSPECTION INSPECT IGNITION SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Switch position Specified value terminal number LOCK No continuity 3–4 Continuity 2–3–4 Continuity 9–10 2–4–7 START...
Page 334 BE–15 BODY ELECTRICAL SYSTEM – KEY UNLOCK WARNING SYSTEM KEY UNLOCK WARNING SYSTEM PARTS LOCATION KEY UNLOCK WARNING SWITCH INSPECTION INSPECT KEY UNLOCK WARNING SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Condition Specified value terminal number Switch OFF No continuity (Key removed)
Page 335 BE–16 BODY ELECTRICAL SYSTEM – KEY UNLOCK WARNING SYSTEM INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Relay Circuit/ Key Unlock Warning System Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Tester connection to Condition Specified value (Continuity) terminal number...
Page 336 BE–17 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM PARTS LOCATION...
Page 337 BE–18 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM...
Page 338 BE–19 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 339 BE–20 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TAILLIGHT (USA) Trouble (See page) Parts name 1. Light Control Switch (BE–29) (BE–31) 2. Integration Relay Taillight does not light. (Headlight does not light) 3. Wire Harness 1. TAIL Fuse (BE–4) (BE–30) 2.
Page 340 BE–21 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT (CANADA) Trouble Parts name (See page) Headlight does not light. (Taillight is normal) 1. Wire Harness Headlight does not light. 1. MAIN FL (Taillight does not light up) 2. Wire Harness 1.
Page 341 BE–22 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TAILLIGHT (CANADA) (See page) Trouble Parts name (BE–29) 1. Light Control Switch Taillight does not light. (BE–31) 2. Integration Relay (Headlight does not light) 3. Wire Harness (BE–4) 1. TAIL Fuse (BE–30) 2.
Page 342 BE–23 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AIM ADJUSTMENT COMBINATION SWITCH REMOVAL See page BO–108.
Page 343 BE–24 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH DISASSEMBLY Components...
Page 344 BE–25 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM 1. REMOVE WIRE HARNESS HOLDER NO.1 2. REMOVE TERMINALS FROM CONNECTOR (a) Release the 4 tabs and open the terminal cover. NOTICE: Do not remove terminal for SRS connector (Yellow). (b) From the open end, insert a miniature screwdriver between the locking lug and terminal.
Page 345 BE–26 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM 5. REMOVE WIRE HARNESS CLAMP Remove the screw and the wire harness clamp. 6. REMOVE LIGHT CONTROL AND FOG LIGHT SWITCH (a) Remove the 2 screws and the ball set plate from the switch body.
Page 346 BE–27 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH ASSEMBLY INSTALL PARTS OF COMBINATION SWITCH IN RE– VERSE SEQUENCE OF DISASSEMBLY (MAIN POINT OF ASSEMBLY) 1. INSTALL LIGHT CONTROL SWITCH (a) Slide the switch and install the switch body. (b) Set the lever in the HI position, and install the ball and plate.
Page 347 BE–28 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH INSTALLATION For installation, follow the removal procedure in re– verse. (MAIN POINT OF INSTALLATION) ADJUSTMENT OF SPIRAL CABLE (a) Check that the front wheels are facing straight ahead. (b) Turn the spiral cable counterclockwise by hand until it becomes harder to turn the cable.
Page 348 BE–29 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH INSPECTION 1. INSPECT LIGHT CONTROL SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Specified value Switch position terminal number No continuity A2 – All TAIL Continuity A2 –All –A13 HEAD Continuity...
Page 349 BE–30 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT CONTROL RELAY INSPECTION INSPECT HEADLIGHT CONTROL RELAY Continuity Inspect the relay continuity between terminals. Tester connection to Condition Specified value terminal number 1–2 Continuity Constant Apply B + between 3–4 Continuity terminals 1 and 2.
Page 350 BE–31 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Relay Circuit/ Light Auto Turn Off System Remove the relay from junction block and inspect the connectors on the wire harness and junction block side, as shown in the chart. Tester connection to Specified value (Continuity) Condition...
Page 351 BE–32 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY (MAIN) INSPECTION (for CANADA) INSPECT DAYTIME RUNNING LIGHT RELAY (MAIN) Circuit/ Wire Harness Side Disconnect the connector from relay and inspect the connector on wire harness side, as shown. Tester connection to Condition Specified value (Continuity)
Page 352 BE–33 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY NO.2 INSPECTION (for CANADA) INSPECT DAYTIME RUNNING LIGHT RELAY NO.2 Continuity Inspect the relay continuity between terminals. Tester connection to Specified value Condition terminal number 1–4 Continuity Constant 2–4 Apply B + between...
Page 353 BE–34 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY NO.4 INSPECTION INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 Continuity Tester connection to Specified value Condition terminal number 1–2 Continuity Constant Apply B + between 3–4 Continuity terminals 1 and 2. If continuity is not as specified, replace the relay.
Page 354 BE–35 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM PARTS LOCATION...
Page 355 BE–36 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM...
Page 356 BE–37 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 357 BE–38 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL SWITCH See page BE–29. HAZARD WARNING SWITCH INSPECTION INSPECT HAZARD WARNING SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Specified value Condition terminal number Switch OFF Continuity 7–10...
Page 358 BE–39 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM PARTS LOCATION...
Page 359 BE–40 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM...
Page 360 BE–41 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 361 BE–42 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM PERSONAL LIGHT INSPECTION INSPECT PERSONAL LIGHT SWITCH Continuity Inspect the light switch continuity between terminals. Tester connection to Switch position Specified value terminal number No continuity 1–2 Continuity 1 –(4) The number in bracket ( ) applies to vehicles with Sliding Roof System.
Page 362 BE–43 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM DOOR OUTSIDE HANDLE SWITCH INSPECTION INSPECT DOOR OUTSIDE HANDLE SWITCH (a) Check that there is continuity between terminals 1 and 2 when door outside handle is pulled. (b) Check that there is no continuity between terminals 1 and 2 when door outside handle is released.
Page 363 BE–44 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM LUGGAGE DOOR COURTESY SWITCH INSPECTION INSPECT LUGGAGE DOOR COURTESY SWITCH Continuity Inspect the switch continuity between terminal and switch body. Tester connection to Condition Specified value terminal number Switch OFF No continuity Switch ON 1 –...
Page 364 BE–45 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM BACK–UP LIGHT SYSTEM PARTS LOCATION...
Page 365 BE–46 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM...
Page 366 BE–47 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 367 BE–48 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM STOP LIGHT SYSTEM PARTS LOCATION...
Page 368 BE–49 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM...
Page 369 BE–50 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM TROUBLESHOOTING The. table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 370 BE–51 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM PARTS LOCATION...
Page 371 BE–52 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 372 BE–53 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM COMBINATION SWITCH REMOVAL See page BO–108 COMBINATION SWITCH DISASSEMBLY See page BE–25. COMBINATION SWITCH ASSEMBLY See page BE–27. COMBINATION SWITCH INSTALLATION See page BO–108. COMBINATION SWITCH INSPECTION INSPECT WIPER AND WASHER SWITCH Continuity Inspect the switch continuity between terminals.
Page 373 BE–54 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER HI Tester connection to Specified value Switch position terminal number B6 B16 MIST OFF Continuity B13–B18 B6 B16 MIST ON Continuity B13–B18 WASHER Tester connection to Switch position Specified value terminal number No continuity B8–B16...
Page 374 BE–55 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM (e) After connecting terminal B–4 to terminal B–18, connect to terminal B–16. Then, check that the voltage rises from 0 V to battery positive voltage within the times, as shown in the table.
Page 375 BE–56 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER RELAY INSPECTION WAGON Only: INSPECT REAR WIPER RELAY Continuity (a) Check that there is continuity between terminals 4 and 6. (b) Check that there is continuity between terminals 1 and 2. (c) Check that there is no continuity between terminals 1 and 4.
Page 376 BE–57 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM Operation, Stopping at Stop Position (a) Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3. (b) Connect terminals 3 and 5.
Page 377 BE–58 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WASHER MOTOR INSPECTION (WAGON Only) INSPECT WASHER MOTOR Front Washer Operation Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out.
Page 378 BE–59 BODY ELECTRICAL SYSTEM – COMBINATION METER COMBINATION METER PARTS LOCATION...
Page 379 BE–60 BODY ELECTRICAL SYSTEM – COMBINATION METER WIRING DIAGRAM...
Page 380 BE–61 BODY ELECTRICAL SYSTEM – COMBINATION METER Wiring Connector Side Headlight dimmer and turn signal switch Headlight dimmer and turn signal switch Ground Ground Ground Fuel sender gauge–terminal 2 Fuel sender gauge–terminal 3 Cruise Control ECU 0/D OFF Switch Electronic Controlled Transaxle (PWR) Speed sensor Light control rheostat Light failure sensor...
Page 381 BE–62 BODY ELECTRICAL SYSTEM – COMBINATION METER A/T SHIFT POSITION INDICATOR Wiring Connector Side Light control rheostat TAIL fuse Park/Neutral Position switch Park/Neutral Position switch Park/Neutral Position switch Ground Park/Neutral Position switch GAUGE fuse 0/D switch Park/Neutral Position switch Park/Neutral Position switch Electronic Controlled Transaxle select switch (PWR)
Page 382 BE–63 BODY ELECTRICAL SYSTEM – COMBINATION METER TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 383 BE–64 BODY ELECTRICAL SYSTEM – COMBINATION METER WARNING LIGHTS Trouble Parts name (See page) (BE–4) 1. GAUGE Fuse (BE–61) 2. Combination Meter Wiring Circuit Warning light do not fight up. (Except. Discharge) 3. Wire Harness 1. Bulb 2. Combination Meter Wiring Circuit (BE–61) Low Oil Pressure warning light does not light up.
Page 384 BE–65 BODY ELECTRICAL SYSTEM – COMBINATION METER INDICATOR LIGHTS (see page) Parts name Trouble 1. Bulb 2. Combination Meter Wiring Circuit (BE–61) 3. O/D OFF Switch 5S–FE (AX1–102) O/D OFF indicator light does not light up. 1 MZ–FE (AX2–130) 4. Wire Harness 1.
Page 385 BE–66 BODY ELECTRICAL SYSTEM – COMBINATION METER SPEEDOMETER INSPECTION ON–VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer.
Page 386 BE–67 BODY ELECTRICAL SYSTEM – COMBINATION METER SPEED SENSOR INSPECTION Operation (a) Connect the positive (+) lead from battery to terminal 1 and negative (–) lead to terminal 2. (b) Connect the positive (+) lead from tester to terminal 3 and negative (–) lead to terminal 2.
Page 387 BE–68 BODY ELECTRICAL SYSTEM – COMBINATION METER TACHOMETER INSPECTION ON–VEHICLE (a) Connect a tune–up test tachometer, and start the engine. NOTICE: Reversing the connection of the tachometer will damage the transistors and diodes inside. (b) Compare the tester and tachometer indications. If error is excessive, replace the tachometer.
Page 388 BE–69 BODY ELECTRICAL SYSTEM – COMBINATION METER FUEL SENDER GAUGE INSPECTION Operation (a) Connect a series of three 1.5 V dry cell batteries. (b) Connect the positive (+) lead from the dry cell batte– ries to terminal 2 through a 3.4 W test bulb and the negative (–) lead to terminal 3.
Page 389 BE–70 BODY ELECTRICAL SYSTEM – COMBINATION METER (b) Submerge the switch in fuel, check that the bulb goes out. If operation is not as specified, replace the sender gauge. ENGINE COOLANT TEMPERATURE RECEIVER GAUGE AND SENDER GAUGE INSPECTION Operation (a) Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, check that the receiver gauge needle indicates COOL.
Page 390 BE–71 BODY ELECTRICAL SYSTEM – COMBINATION METER LOW OIL PRESSURE WARNING LIGHT INSPECTION INSPECT LOW OIL PRESSURE WARNING LIGHT (a) Disconnect the connector from the warning switch and ground terminal on the wire harness side connec– tor. (b) Turn the ignition switch ON, check that the warning light lights up.
Page 391 BE–72 BODY ELECTRICAL SYSTEM – COMBINATION METER BRAKE FLUID LEVEL WARNING SWITCH INSPECTION INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Check that there is no continuity between terminals with the switch OFF (float up).
Page 392 BE–73 BODY ELECTRICAL SYSTEM – COMBINATION METER LIGHT FAILURE SENSOR INSPECTION INSPECT LIGHT FAILURE SENSOR Relay Circuit Disconnect the connector from the sensor and in– spect the connector on the wire harness side, as shown. Tester connection to Specified value (Continuity) Condition terminal number * Continuity...
Page 393 BE–74 BODY ELECTRICAL SYSTEM – COMBINATION METER OPEN DOOR WARNING LIGHT INSPECTION INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch, and ground terminal 1 on the wire harness side connector and check that the warning light lights If the warning light does not light up, inspect the bulb or wire harness.
Page 394 BE–75 BODY ELECTRICAL SYSTEM – COMBINATION METER INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Operation/ Seat belt warning (a) Connect the positive (+) lead from the battery to terminals Al and A7. (b) Connect the terminal A7 to terminal A9 through the 3.4 W test bulb.
Page 395 BE–76 BODY ELECTRICAL SYSTEM – COMBINATION METER Tester connection to Condition Specified value (Voltage) terminal number A1 – Ground Battery positive voltage Constant A7 – Ground Ignition switch position OFF or ACC No voltage A9 – Ground A7 – Ground Ignition switch position ON Battery positive voltage A9 –...
Page 396 BE–77 BODY ELECTRICAL SYSTEM – COMBINATION METER w/ POWER SEAT: Continuity (a) Check that there is continuity between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). ’ (b) Check that there is no continuity between terminals 1 and 2 on the switch side connector with the switch OFF (belt unfastened).
Page 397 BE–78 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM DEFOGGER SYSTEM PARTS LOCATION...
Page 398 BE–79 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 399 BE–80 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM DEFOGGER RELAY INSPECTION INSPECT DEFOGGER RELAY Continuity Inspect the relay continuity between terminals. Tester connection to Condition Specified value terminal number 1–2 Continuity Constant Apply B + between Continuity 3–5 terminals 1 and 2. If continuity is not as specified, replace the relay.
Page 400 BE–81 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM (d) Place the voltmeter positive (+) lead against the def– ogger positive (+) terminal. (e) Place the voltmeter negative (–) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (–) terminal end.
Page 401 BE–82 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM PARTS LOCATION...
Page 402 BE–83 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 403 BE–84 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM POWER WINDOW MASTER SWITCH INSPECTION INSPECT POWER WINDOW MASTER SWITCH Continuity Inspect the switch continuity between terminals. Front Driver’s Switch (Window unlock)/ Continuity Tester connection to Switch position Specified value terminal number 6–7–8 Continuity 1 –2–13...
Page 404 BE–85 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Rear Left Switch (Window unlock)/ Continuity Tester connection to Specified value Switch position terminal number 7–8–10 Continuity 9–10 Continuity DOWN Continuity 7–8–9 Rear Left Switch (Window lock)/ Continuity Tester connection to Specified value Switch position terminal number...
Page 405 BE–86 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Illumination (a) Set the window lock switch to the unlock position. (b) Connect the positive (+) lead from the battery to terminal 7 and the negative (–) lead to terminal 1, check that all the illuminations light up.
Page 406 BE–87 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM (e) Check that the current increases approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be made before the circuit breaker operates.
Page 407 BE–88 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM (d) Reverse the polarity, check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. Front Passenger’s Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns counterclockwise.
Page 408 BE–89 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Rear Left Side Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2. check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun–...
Page 409 BE–90 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM PARTS LOCATION...
Page 410 BE–91 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM...
Page 411 BE–92 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 412 BE–93 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM POWER WINDOW MASTER SWITCH INSPECTION INSPECT POWER WINDOW MASTER SWITCH Master Switch: Driver’s Door Lock Manual Switch/ Continuity Inspect the switch continuity between terminals. Tester connection to Switch position Specified value terminal number LOCK 1–2–4...
Page 413 BE–94 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR KEY LOCK AND UNLOCK SWITCH INSPECTION INSPECT DOOR KEY LOCK AND UNLOCK SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Switch position Specified value terminal number LOCK Continuity 2–3...
Page 414 BE–95 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM Ex. WAGON: PTC THERMISTOR OPERATION INSPECTION USING AN AMMETER (a) Connect the positive (+) lead from the battery to terminal 2. (b) Connect the positive (+) lead from the ammeter to terminal 4 and the negative (–) lead to battery nega–...
Page 415 BE–96 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM WAGON Only: PTC THERMISTOR OPERATION INSPECTION USING AN AMMETER (a) Connect the positive (+) lead from the battery to terminal 2. (b) Connect the positive (+) lead from the ammeter to terminal 4 and the negative (–) lead to battery nega–...
Page 416 BE–97 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR UNLOCK DETECTION SWITCH INSPECTION INSPECT DOOR UNLOCK DETECTION SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Switch position Specified value terminal number OFF (Door lock set No continuity to LOCK) ON (Door lock set...
Page 417 BE–98 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR LOCK CONTROL RELAY INSPECTION INSPECT DOOR LOCK CONTROL RELAY Relay Circuit Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart.
Page 418 BE–99 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM Tester connection to Specified value (Continuity) Condition terminal number Passenger’s door courtesy switch position No continuity 14 – Ground OFF (Door closed) Passenger’s door courtesy switch position Continuity 14– Ground ON (Door opened) Continuity 16 –...
Page 419 BE–100 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM DESCRIPTION Standby Operation Current flows from the DOME fuse to terminal 12 of the sliding roof control relay (hereafter called relay). When the ignition switch is ON, the current flows from the power main relay to terminal 6 of the relay.
Page 420 BE–101 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM 5. TILT DOWN operation When the switch on the ”DOWN” side of the control switch is pushed, continuity is produced between terminal 7 of the relay and body ground. Then the relay operates, the current flows through terminal6 of the relay –...
Page 421 BE–102 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 422 BE–103 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM SLIDING ROOF SWITCH INSPECTION INSPECT SLIDING ROOF SWITCH Continuity Inspect the switch continuity between terminals. Tester connection to Switch position Specified value terminal number 3–4 Continuity SLIDE OPEN SLIDE OFF No continuity SLIDE CLOSE 4–6 Continuity...
Page 423 BE–104 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM (b) With the sliding roof in fully opened position, hold the sliding roof switch in ”CLOSE” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. SLIDING ROOF CONTROL RELAY INSPECTION INSPECT SLIDING ROOF CONTROL RELAY...
Page 424 BE–105 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM Continuity 11 – Ground Constant Tester connection to Condition Specified value (Voltage) terminal number *No voltage Ignition switch position LOCK or ACC 6 – Ground Ignition switch position ON Battery positive voltage 6 –...
Page 425 BE–106 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM PARTS LOCATION...
Page 426 BE–107 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 427 BE–108 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM MIRROR SWITCH INSPECTION INSPECT MIRROR SWITCH Continuity Inspect the switch continuity between terminals. LEFT SIDE Tester connection to Switch position Specified vaIue terminal number No continuity Continuity Continuity DOWN LEFT Continuity RIGHT Continuity Tester connection to...
Page 428 BE–109 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM MIRROR MOTOR INSPECTION INSPECT MIRROR MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns upward. (b) Reverse the polarity, check that the mirror turns to downward.
Page 429 BE–110 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM PARTS LOCATION...
Page 430 BE–111 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty.
Page 431 BE–112 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM POWER SEAT SWITCH INSPECTION INSPECT POWER SEAT SWITCH Continuity Inspect the switch continuity between terminals. SLIDE SWITCH Tester connection to Switch position Specified value terminal number 5–10 Continuity FRONT 8–9 5–9 Continuity 8–9 5–9...
Page 432 BE–113 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM SLIDE MOTOR INSPECTION INSPECT SLIDE MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun–...
Page 433 BE–114 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to descend.
Page 434 BE–115 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM RECLINING MOTOR INSPECTION (Except 2–door) INSPECT RECLINING MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun–...
Page 435 BE–116 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM AUDIO SYSTEM SYSTEM DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: 30 kHz 300kHz 30 MHz 300 MHz 3 MHz Frequency Designation Radio wave Frequency modulation Amplitude modulation Modulation method LF: low Frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency...
Page 436 BE–117 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 3. RECEPTION PROBLEMS Besides the problem of static, there are also the prob– lems called ”fading”, ”rnultipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, espe–...
Page 437 BE–118 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 4. COMPACT DISC PLAYER Compact Disc (hereafter called ”CD”) Players use a laser beam pick–up to read the digital signals recor– ded on the CD and reproduce analog signals of the music, etc. There are 4.7 in. (12 cm) and 3.2 in. (8 cm) discs in the CD player.
Page 438 BE–119 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM ANTI–THEFT SYSTEM HINT: The words ”ANTI–THEFT SYSTEM” are dis– played on the cassette tape slot cover. For operation instructions for the anti–theft system, please consult the audio system section in the Owner’s Manual (hereafter called O/M). 1.
Page 439 BE–120 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM PARTS LOCATION...
Page 440 BE–121 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM...
Page 441 BE–122 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM TROUBLESHOOTING NOTICE: When replacing the internal mechanism (ECU part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC etc. of the replacement part (spare part), HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for...
Page 442 BE–123 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM HOW TO USE DIAGNOSTIC CHART Reference: Radio NO POWER COMING IN Check if RADIO fuse is OK? Replace fuse Check if DOME fuse is OK? Replace fuse Is ACC applied to radio? ACC wire harness faulty Check if GND (Wire harness side) to GND wire harness faulty radio is OK?
Page 443 BE–124 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Troubleshooting for ANTI–THEFT SYSTEM Turn Ignition key from LOCK position to ACC position. Display A: Display E: Display B. I D Number is set. ANTI–THEFT SYSTEM operation condition. (ID number input error 10 times or more.) ”SEC”...
Page 444 BE–125 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM RADIO NOT OPERATING WHEN POWER SWITCH Radio TURNED TO ’ON’ Replace fuse. Check if RADIO fuse is OK? ACC wire harness faulty. Is ACC applied to radio ? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty.
Page 445 BE–126 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Is tape player operating normally? Check if RADIO fuse is OK? Replace fuse. ACC wire harness faulty. Is ACC applied to radio? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty.
Page 446 BE–127 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Is tape player operating normally? Replace fuse. Check if RADIO fuse is OK? ACC wire harness faulty. Is ACC applied to power amplifier? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty.
Page 447 BE–128 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED TO Radio ’ON’, BUT NO SOUND (INCLUDING ’NOISE’) IS PRODUCED Check if RADIO fuse is 0K? Replace fuse. Is ACC applied to radio? ACC wire harness faulty. Check if DOME fuse is OK? Replace fuse.
Page 448 BE–129 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Is tape player operating normally? Radio faulty. Replace fuse. Check if RADIO fuse is OK? ACC wire harness faulty. Is ACC applied to radio? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty. Is + B applied to radio? Check if GND (wire harness side) to radio is OK? GND faulty.
Page 449 BE–130 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Is tape player operating normally? Is power for the antenna being output from the tape player? Is power for the antenna being Radio assembly output from the power faulty. amplifier? If power amplifier side faulty Power amplifier faulty.
Page 450 BE–131 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE !s there continuity in speaker wire harness? Speaker wire harness faulty. Temporarily install another speaker. Functions OK? Speaker faulty. Hissing sound from speaker? Power amplifier faulty. Recheck system after repair. Radio assembly faulty.
Page 451 BE–132 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Is tape player operating normally? Radio assembly faulty. Is hiss produced by non–functioning speaker? Speaker wire harness faulty. Is there continuity in speaker wire harness? Speaker faulty. Temporarily install another speaker. Functions OK? Radio assembly faulty.
Page 452 BE–133 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM EITHER AM OR FM DOES NOT WORK, RECEPTION Radio POOR (VOLUME FAINT), FEW PRESET TUNING BANDS Problem with radio wave signals or location? Poor signals, poor location. Are both AM or FM defective? Radio faulty.
Page 453 BE–134 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Is tape player operating normally? Radio assembly faulty. Temporarily install another speaker. Functions OK? Speaker faulty. Radio assembly faulty. Problem with radio wave signals or location? Poor signals, poor location. Are both AM and FM defective? Radio assembly faulty.
Page 454 BE–135 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio SOUND QUALITY POOR Is sound quality always bed? Is sound quality bad in certain Poor signals, poor area only? location. Radio faulty. is speaker properly installed? Install properly. Temporarily install another speaker. Functions OK? Speaker faulty.
Page 455 BE–136 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Speaker faulty. Temporarily install another speaker. Functions OK? Radio assembly faulty. Is sound quality bad in Poor signals, poor Is sound quality always bad? location. certain areas only? Is tape player operating normally? Radio assembly faulty.
Page 456 BE–137 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio PRESET MEMORY DISAPPEARS Check if DOME fuse is OK? Replace fuse. Is + B applied to radio? + B wire harness faulty. Check if GND (wire harness side) to radio? GND faulty. Radio faulty.
Page 457 BE–138 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Can cassette tape be inserted in tape player? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty. Is + B applied to power amplifier? GND faulty. Check if GND (wire harness side) to power amplifier? Power amplifier faulty.
Page 458 BE–139 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Tape Player CASSETTE TAPE CANNOT BE INSERTED Is there a foreign object inside tape player? Remove foreign object. Is auto search button of radio operating normally? Radio assembly faulty. Check if DOME fuse is OK? Replace fuse.
Page 459 BE–140 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE + B wire harness faulty. Is + B applied to power amplifier? Check if GND (wire harness side) to power amplifier is OK? GND faulty. Power amplifier faulty. Is + B applied to radio assembly Power amplifier faulty.
Page 460 BE–141 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Is radio operating normal? Replace fuse. Check if RADIO fuse is OK? ACC wire harness faulty. Is ACC applied to power amplifier? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty.
Page 461 BE–142 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM POWER COMING IN, BUT TAPE PLAYER NOT Tape Player OPERATING Functions OK if different cassette tape inserted? Cassette tape faulty. Is radio operating normally? Radio assembly faulty. Is there continuity in speaker wire harness? Speaker wire harness faulty.
Page 462 BE–143 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Temporarily install another speaker. Speaker faulty. Function OK? Hissing sound from speaker? Power amplifier faulty. Recheck system after repair. Radio assembly faulty. Recheck system after repair. Tape Player EITHER SPEAKER DOES NOT WORK Is radio operating normally? Radio assembly faulty.
Page 463 BE–144 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Radio assembly faulty. Is radio operating normally? Radio assembly faulty. Is hiss produced by non–functioning speaker? Recheck system after repair. Speaker wire harness faulty. Is there continuity in speaker wire harness? Speaker faulty. Temporarily install another speaker.
Page 464 BE–145 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Temporarily install another speaker. Speaker faulty. Function OK? Radio assembly faulty. Functions OK different cassette tape inserted? Cassette tape faulty. Operates normally after cleaning the heads? Head dirty. Is radio operating normally? Radio assembly faulty.
Page 465 BE–146 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM TAPE JAMMED MALFUNCTION WITH TAPE SPEED Tape Player OR AUTO–REVERSE Function OK if different tape (less than 120 mins.) is inserted? Cassette tape faulty. Is there a foreign abject inside tape player? Remove foreign object. Operates normally after cleaning the heads? Head dirty.
Page 466 BE–147 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Cassette tape jammed. Is tape player operating normally? Radio assembly faulty. Is auto search button of radio operating normally? Replace fuse. Check if DOME fuse is OK? + B wire harness faulty. !s + B applied to power amplifier? Power amplifier faulty.
Page 467 BE–148 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Is +B applied to power amplifier? +B wire harness faulty. Check if GND (wire harness side) to radio assembly is OK? Radio assembly faulty. CD Player CD INSERTS, BUT NO POWER Is radio operating normally? Is ACC applied to CD player? Radio assembly...
Page 468 BE–149 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE CONTINUED FROM PREVIOUS PAGE Formation of condensation Has sudden temperature change due to temp. change. occurred inside cabin? CD player faulty. Speaker wire harness faulty. Is there continuity in speaker wire harness? Speaker faulty.
Page 469 BE–150 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CD Player SOUND QUALITY POOR (VOLUME FAINT) Functions OK if different CD inserted? CD faulty. Is radio operating normally? CD player faulty. Is speaker properly installed? Install properly. Temporarily install another speaker. Speaker faulty. Functions OK? Radio assembly or CD player or Power amplifier faulty.
Page 470 BE–151 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CD Player CD WILL NOT EJECT Is auto search button of radio operating Is + B applied to CD player? Radio assembly normally? faulty. CD player faulty. Check if DOME fuse is OK? Replace fuse.
Page 471 BE–152 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Motor Antenna Type Does antenna extend when radio switched ON? Temporarily install another antenna. Motor antenna Functions OK? faulty. Radio side faulty. Inspect antenna motor. Antenna motor faulty. Inspect antenna motor control relay. (Relay circuit) Relay faulty.
Page 472 BE–153 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Inspect antenna motor. Antenna motor faulty. Relay faulty. Inspect antenna motor control relay. (Relay circuit) Relay circuit faulty. Is power related to the antenna being input to the antenna motor control relay? Wire harness faulty.
Page 473 BE–154 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Noise NOISE PRODUCED WHEN ENGINE STARTS Whistling noise which becomes high–pitched when accelerator Generator noise. strongly depressed, disappears shortly after engine stops. Whining noise occurs when A/C is operating. A/C noise. Scratching noise occurs during sudden acceleration, driving on Fuel gauge noise.
Page 474 BE–155 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM MOTOR ANTENNA REMOVAL AND INSTALLATION 1. REMOVE MOTOR ANTENNA (a) Remove the antenna nut. (b) Remove the RH side cover. (c) Disconnect the motor antenna connector. (d) Remove the nut and the motor antenna assembly. (e) Disconnect the antenna cord.
Page 475 BE–156 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 2. INSTALL ANTENNA ROD (a) Insert the cable of the rod until it reaches the bottom. HINT: When inserting the cable, the teeth on the cable must face toward the rear of the vehicle. Insert the cable approx.
Page 476 BE–157 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Tester connection to Condition Specified value (Continuity) terminal number 1 – Ground Continuity Constant If circuit is not as specified, inspect radio or wire harness. If circuit is as specified, replace motor antenna. 2.
Page 477 BE–158 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 3. INSPECT ANTENNA MOTOR CONTROL RELAY Relay Circuit Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart. Tester connection to Condition Specified value (Continuity) terminal number 1–4 Continuity...
Page 478 BE–159 BODY ELECTRICAL SYSTEM – CLOCK CLOCK TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Clock will not operate Clock loses or gains time 1.5 seconds/day CLOCK WILL NOT OPERATE (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery.
Page 479 BE–160 BODY ELECTRICAL SYSTEM – CLOCK Open or short circuit in wire harness Is there battery positive voltage between terminal + B and body between terminal + B and DOME fuse. ground? Is there continuity between terminal GND and body ground? Open circuit in wire harness between terminal GND and body ground.
Page 480 BE–161 BODY ELECTRICAL SYSTEM – CLOCK – MEMO –...
Page 481 BE–162 BODY ELECTRICAL SYSTEM – CLOCK –MEMO –...
Page 482 BE–163 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM...
Page 483 BE–164 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DESCRIPTION The cruise control system is standard, which is convenient when driving continuously at a constant speed. The cruise control ECU controls all cruise control functions. A diagnosis function is built in. In the unlikely event of a malfunction in the system, the problem area is detected by the cruise control ECU and it causes the power indicator light on the combination meter to blink, warning the driver that there is an abnormality as well as storing a malfunction code in the ECU memory for the service technician to retrieve.
Page 484 BE–165 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following page. 1. CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 485 Matrix Chart of Problems Symptoms BE–171 BE–178 Input Signal Parts Inspection Circuit Inspection Check BE–190 BE–231 Identification of Problem Repair Confirmation Test : Diagnostic steps permitting the use of Step 2 , 5 , 8 , 10 the TOYOTA hand–held tester or TOYOTA break–out–box.
Page 486 BE–167 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CUSTOMER PROBLEM ANALYSIS CHECK SHEET...
Page 487 BE–168 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM INDICATOR CHECK 1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when the cruise control main switch is turned on, and that the indicator light goes oft when the main switch is turned OFF.
Page 488 CRUISE CONTROL SYSTEM ECU DATA MONITOR USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Monitor the ECU data by following the prompts on the tester screen. HINT: TOYOTA hand–held tester had a ”Snapshot”...
Page 489: Actuator Motor Circuit
BE–170 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CRUISE MAIN Indicator Diagnosis Code No. Light Blinking Pattern Normal Duty ratio of 100% output to motor acceleration side. Overcurrent (short) in motor circuit. Overcurrent (short) in magnet clutch circuit. Open in magnet clutch circuit.
Page 490: Table Of Contents
BE–171 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the page given. Circuit Inspection Code No.
Page 491 BE–172 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INPUT SIGNAL CHECK Output of Code 1. (a) For check No. 1 – No.2 Turn the ignition switch on. (b) For check No.3 – No.7 (1) Turn the ignition switch on. (2) Shift to D position. (e) For check No.8 –...
Page 492 BE–173 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 493 BE–174 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM...
Page 494 BE–175 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM TERMINALS OF ECU CRUISE Control ECU Terminal Name Symbol Terminal Name Symbol Power Source Stop Light Switch Park/Neutral Position Switch or Clutch Switch Backup Power Source Stop Light Switch Parking Brake Switch Cruise Main Switch CRUISE Control Switch CRUISE MAIN Indicator Light...
Page 495 BE–176 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM STANDARD VALUE OF ECU TERMINAL Wiring Standard Terminals Symbols Condition Color Value Always IG ON. Depress clutch pedal or P or N positions IG ON. Release clutch pedal and other positions. IG ON. Parking brake is operating. IG ON.
Page 496 BE–177 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Wiring Standard Condition Symbols Terminals color Value Depress brake pedal. Release brake pedal. IG ON. Main switch ON. Switch neutral position. IG ON. Main switch ON. CANCEL Switch hold ON. IG ON. Main switch ON. SET/COAST Switch hold ON.
Page 497 BE–178 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs (re- appears), perform troubleshooting for each problem symptom, checking the circuits for each symptom in the order given in the table below.
Page 498 BE–179 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM HINT: 1. If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. 2.
Page 499 BE–180 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM LOCATION OF CONNECTORS Location of Connectors in Engine Compartment...
Page 500 BE–181 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM 1 MZ–FE...
Page 501 BE–182 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM 5S–FE...
Page 502 BE–183 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM 5S–FE...
Page 503 BE–184 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Location of Connectors in Instrument Panel...
Page 504 BE–185 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM...
Page 505 BE–186 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Location of Connectors in Instrument Panel...
Page 506 BE–187 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM_ J/B No. 1...
Page 507 BE–188 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM JI6 No.3...
Page 508 BE–189 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Location of Connectors in Body...
Page 509 BE–190 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CIRCUIT INSPECTION DTC 11 13 Actuator Motor Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION The actuator motor is operated by signals from the EC U. Acceleration and deceleration signals are transmitted by changes in the Duty Ratio (See note below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle.
Page 510 BE–191 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check actuator motor. 1. Remove cruise control actuator. 2. Disconnect actuator connector. 1. Connect positive + lead to terminal 5 and negative – lead to terminal 4 of actuator connector. (Magnet clutch ON) 2.
Page 511: Actuator Magnet Clutch Circuit
BE–192 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 12 Actuator Magnet Clutch Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION This circuit turns on the magnet clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control, the rotor shaft between the motor and control plate is released.
Page 512 BE–193 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM...
Page 513 BE–194 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check actuator magnet clutch. 1. Remove cruise control actuator. 2. Disconnect actuator connector. Move the control plate by hand. Control plate moves. (Magnet clutch off) 1. Connect positive + lead to terminal 5 and negative –...
Page 514 BE–195 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 515: Actuator Position Sensor Circuit
BE–196 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 13 Actuator Position Sensor Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION This circuit detects the rotation position of the actuator control plate and sends signal to the ECU. Trouble area Diagnosis Code No. Cruise control actuator Position sensor.
Page 516 BE–197 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals VR2 and VR3 of cruise control ECU connector. Remove cruise control ECU with connectors still connected. 1 Turn ignition switch on. 2. Measure voltage between terminals VR2 and VR3 of cruise control ECU connector while turning control plate slowly by hand from the deceleration side to the acceleration side.
Page 517: Speed Sensor Circuit
BE–198 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 21 23 Speed Sensor Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION The speed sensor signal is sent to cruise control ECU as vehicle speed sig- nal. Trouble area Diagnosis Code No. Speed signal is not input to the ECU Speed sensor Combination meter Harness or connector between speed sensor...
Page 518 BE–199 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM...
Page 519 BE–200 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Input signal check. 1 See input signal check on page BE–172. 2. Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph).
Page 520 BE–201 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 521 BE–202 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 32 34 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. Code No. Diagnosis Trouble area Short in, control switch circuit.
Page 522 BE–203 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Input signal check. 1 See input signal check on page BE–172. Input signal Indicator light 2. Check the indicator light operation when each blinking pattern of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON.
Page 523 BE–204 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check control switch. 1 Remove steering wheel center pad. 2. Disconnect control switch connector. Measure resistance between terminals 3 and 4 of control switch connector when control switch is operated. Resistance Switch position 1 Mn or higher Neutral RES/ACC...
Page 524 BE–205 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 525 BE–206 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Stop Light Switch Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When the brake is on, battery voltage normally applies through the stop fuse and stop switch to terminal STP– of the ECU, and the ECU turns the cruise control off. A fail–safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit.
Page 526 BE–207 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM...
Page 527 BE–208 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of stop light. Check that stop light comes on when brake pedal is depressed, and turns off when brake pedal is released. Check stop light circuit (See page BE–50).
Page 528 BE–209 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 529 BE–210 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Idle Switch Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to enable accurate cruise control at the set speed quickly. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine.
Page 530 BE–211 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminal IDL of cruise control ECU connector and body ground. 1. Remove cruise control ECU with connectors still connected. 2. Disconnect ECM and ABS & TRAC ECU con– nector.
Page 531 BE–212 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM_ Electronically Controlled Transaxle Communication Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When driving uphill under cruise control, in order to reduce shifting due to ON–OFF overdrive opera– tion and to provide smooth driving, when down shifting in the electronically controlled transaxle oc– curs, a signal to prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the ECM.
Page 532 BE–213 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM...
Page 533 BE–214 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of overdrive. Test drive after engine warm up. Check that overdrive ON H OFF occurs with operation of OD switch ON–OFF. Check and Repair Electronically Con- trolled Transaxle (See page AX Section). Check voltage between terminal OD of harness side connector of cruise control ECU and body ground.
Page 534 BE–215 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). 1. Connect cruise control electronically controlled transaxle connector. 2. Test drive after engine warm up. Check voltage between terminal ECT of cruise control ECU connector and body ground when OD switch is on and off.
Page 535 BE–216 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Parking Brake Switch Circuit CIRCUIT DESCRIPTION When the parking brake is operating , the parking brake switch sends a signal to the ECU. When this signal is input to the ECU during cruise control driving, the ECU cancels cruise control. DIAGNOSTIC CHART DIAGNOSTIC CHART Check brake warning light...
Page 536 BE–217 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of brake warning light. Check that the brake warning light in the instrument panel comes on when the parking brake is operating with the engine running, and the light goes off when the parking brake is not operating. Check brake warning light circuit (See page BE–64).
Page 537 BE–218 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When the shift position is put in P or N, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. DIAGNOSTIC CHART Proceed to engine trouble–...
Page 538 BE–219 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of starter. Check that the starter operates normally and that the engine starts. Proceed to engine troubleshooting (See page EG Section). Input signal check. 1. See input signal check on page BE–172. 2.
Page 539 BE–220 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Clutch Switch Circuit (5S–FE MT Vehicles) CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the ECU, when this signal is input to the ECU during cruise control driving, the ECU cancels cruise control. DIAGNOSTIC CHART Proceed to engine trouble–...
Page 540 BE–221 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of starter. Check that the starter operates normally and that the engine starts. Proceed to engine troubleshooting (See page EG Section). Input signal check. 1. See input signal check on page BE–172. 2.
Page 541 BE–222 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM ECU Power Source Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator. Terminal GND and the cruise control ECU case are grounded. DIAGNOSTIC CHART Check for short in all the Check ECU–IG fuse.
Page 542 BE–223 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check ECU–IG fuse. Remove ECU–IG fuse from J/B No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and components connected to the ECU–IG fuse (See attached wiring diagram). Check voltage between terminals +B and GND of cruise control ECU connector.
Page 543 BE–224 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check continuity between terminal GND of cruise control ECU connector and body ground. Measure resistance between terminal GND of cruise control ECU connector and body ground. Resistance: Below 1 Repair or replace harness or connector. Check and repair harness and connector between battery and cruise control ECU.
Page 544 BE–225 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM – MEMO –...
Page 545 BE–226 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Back–up Power Source Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION The ECU back–up power source provides power even when the ignition switch is off and is used for diagnostic code memory, etc. DIAGNOSTIC CHART Check for short in all the harness and components Check STOP fuse.
Page 546 BE–227 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check STOP fuse. Remove STOP fuse from JIB No. 1. Check continuity of STOP fuse. Continuity Check for short in all the harness and components connected to the STOP fuse (See attached wiring diagram).
Page 547 BE–228 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Main Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When the cruise control main switch is turned oft, the cruise control does not operate. DIAGNOSTIC CHART Check voltage between terminals CMS Proceed to next circuit and GND of cruise control ECU inspection shown on matrix...
Page 548 BE–229 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals CMS and GND of cruise control ECU connector. 1. Remove cruise control ECU with connectors still connected. 2. Turn ignition switch ON. Measure voltage between terminals CMS and GND of cruise control ECU connector when main switch is hold on and off.
Page 549 BE–230 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM TC Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that diagnostic code output is required. DIAGNOSTIC CHART Proceed to next circuit Check voltage between terminals TC inspection shown on matrix and El of DLC2.
Page 550 BE–231 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals TC and E1 of DLC2. 1. Turn ignition switch ON. 2. Measure voltage between terminals TC and El of DLC2. Voltage: 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178).
Page 551: Actuator Control Cable
BE–232 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Actuator Control Cable Inspection 1. Check that the actuator, control cable and throttle link are properly installed and that the cable and link are connected correctly. 2. Check that the actuator and throttle link are operating smoothly. 3.
Page 552 BO–1 BODY – BODY...
Page 553 BO–2 BODY – GENERAL INFORMATION GENERAL INFORMATION HANDLING PRECAUTIONS Taping When it is possible that the body or parts may be scratched during the operation, apply protection tape before starting work. Example: 1. Before starting work, apply protection tape to body surfaces around parts to be removed and installed.
Page 554 BO–3 BODY – GENERAL INFORMATION ANTI–RUST TREATMENT Anti–rust treatment used on the vehicle body in– cludes body sealer, undercoat, rust inhibitor and paint. HINT: Refer to the Body Collision Damage ’Repair Manual for details of which parts have received anti – rust treatment.
Page 555 BO–4 BODY – GENERAL INFORMATION CLIPS The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/installation...
Page 556 BO–5 BODY – GENERAL INFORMATION CLIPS (Cont’d) Removal/installation Shape (Example)
Page 557 – GENERAL INFORMATION SRS (Supplemental Restraint System) The 1994 CAMRY is equipped with an SRS, such as the driver airbag and front passenger airbag assembly. Failure to carry out service operations in the correct sequence could cause the SRS to deploy, possibly leading to a serious accident.
Page 558 BO–7 BODY – GENERAL INFORMATION The steering wheel must be fitted correctly to the steering column with the spiral cable at the neu– tral position; otherwise, cable disconnection and other troubles may result. Refer to RS section of this manual concerning correct steering wheel installation.
Page 559 BO–8 BODY – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09812–00020 Door Hinge Set Bolt Wrench 09804–24010 Luggage Compartment Door Torsion Bar Tool LUBRICANT Item Capacity Classification MP grease SSM (SPECIAL SERVICE MATERIALS) Front Door 08833–00070 Adhesive 1311, Rear Door THREE BOND 1311 or equivalent Sliding Roof 08850–00070 Windshield glass adhesive set Windshield...
Page 560 BO–9 BODY – PREPARATION 1. CHOOSE SUITABLE ADHESIVE SET Ambient Part No. Part Name temperature Use an adhesive set suitable for the ambient temper– Windshield 0 – 160C ature. o8850–00070 glass adhesive (32 – 59_F) set No. 15 Windshield (59 – 95_F) 08850–00080 glass adhesive set No.
Page 561 BO–10 BODY – FRONT BUMPER FRONT BUMPER COMPONENTS...
Page 562 BO–11 BODY – FRONT BUMPER FRONT BUMPER REMOVAL 1. REMOVE RADIATOR GRILLE Remove 2 screws and the grille. 2. REMOVE CLEARANCE LIGHT (a) Remove the screw. (b) Pull the light forwards to remove it, then disconnect the connector. 3. REMOVE HEADLIGHT (a) Disconnect the connectors.
Page 563 BO–12 BODY – FRONT BUMPER 7. REMOVE ENGINE UNDER COVER (a) Remove the clip (b) Remove 4 screws an the cover. 8. REMOVE INTAKE AIR RESONATOR Remove 2 bolts and the resonator. 9. REMOVE BUMPER COVER (a) Remove 4 clips and the upper retainer. (b) Remove 3 clips and the lower retainer.
Page 564 BO–13 BODY – FRONT BUMPER 11. REMOVE FRONT BUMPER END RETAINER Remove 2 clips and the retainer. 12. REMOVE FRONT BUMPER SIDE SUPPORT (a) Using about 3.2 mm (0.128 in.) drill, drill out 2 rivet heads. (b) Remove the side support. 13.
Page 565 BO–14 BODY – FRONT BUMPER 16. REMOVE FRONT BUMPER ARM Remove 3 nuts and the bumper arm. FRONT BUMPER INSTALLATION INSTALL FRONT BUMPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE 1. INSTALL FOLLOWING PARTS: (a) Front bumper arm Torque: 8.8 N–m (90 kgf–cm, 78 in.–lbf) (b) Front bumper reinforcement Torque: 8.8 N–m (90 kgf–cm, 78in.–lbf) (c) Reinforcement extension...
Page 566 BO–15 BODY – REAR BUMPER REAR BUMPER COMPONENTS...
Page 567 BO–16 BODY – REAR BUMPER COMPONENTS (Cont’d)
Page 568 BO–17 BODY – REAR BUMPER REAR BUMPER REMOVAL 1. REMOVE REAR FLOOR FINISH PLATE Remove the finish plate by pulling. 2. REMOVE REAR LUGGAGE TRIM Using a clip remover, remove 4 clips and the trim. 3. REMOVE RIGHT SIDE LUGGAGE TRIM Using a clip remover, remove 6 clips and the trim.
Page 569 BO–18 BODY – REAR BUMPER 7. REMOVE REAR BUMPER ENERGY ABSORBER Remove the absorber from the bumper cover. 8. REMOVE REAR BUMPER SIDE SUPPORT (a) Using an approx. 3.2 mm (0.26 in.) drill, drill out 3 rivet heads. (b) Remove the side support. 9.
Page 570 BO–19 BODY – REAR BUMPER 12. REMOVE REAR BUMPER ARM (a) Remove 2 grommets. (6) Remove 2 bolts and the bumper arm_ REAR BUMPER INSTALLATION INSTALL REAR BUMPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE 1. INSTALL FOLLOWING PARTS: (a) Rear bumper arm Torque: 79 N–m (810 kgf–cm, 59 ft–lbf) (b) Rear bumper reinforcement...
Page 571 BO–20 BODY – HOOD HOOD HOOD ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock cannot be adjusted with it on. Substitute the bolt with washer for the centering bolt. 1.
Page 572 BO–21 BODY – FRONT DOOR FRONT DOOR COMPONENTS...
Page 573 BO–22 BODY – FRONT DOOR COMPONENTS (Cont’d)
Page 574 BO–23 BODY – FRONT DOOR FRONT DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. SST 09812–00020 2. ADJUST DOOR IN LEFT/ RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust.
Page 575 BO–24 BODY – FRONT DOOR 3. Coupe: REMOVE DOOR COURTESY LIGHT Remove the light by pulling, then disconnect the con– nector. 4. REMOVE DOOR TRIM Sedan, Wagon: HINT: Tape the screwdriver, remove tip before use. (a) Remove 2 clips. (b) Using a screwdriver, remove 2 screw caps and the tweeter cover.
Page 576 BO–25 BODY – FRONT DOOR 5. REMOVE REAR VIEW MIRROR (a) Remove the cover. (b) Remove 3 screws and the mirror. (c) w/ Remote Control Mirror: Disconnect the connector. 6. REMOVE DOOR INSIDE HANDLE (a) Disconnect 2 links. (b) Remove 3 screws and the handle. 7.
Page 577 BO–26 BODY – FRONT DOOR (b) Coupe: Remove 9 screws. (c) Pry out the clip and remove the moulding. 13. REMOVE DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Remove 2 glass mounting bolts. (b) Remove the door glass by pulling it upwards.
Page 578 BO–27 BODY – FRONT DOOR Coupe: (a) Remove 4 nuts and 3 bolts. (b) w/ Power Window: Disconnect the connector. (c) Remove the regulator through the service hole. 17. REMOVE FRONT LOWER FRAME Remove the nut, 2 bolts and the frame. 18.
Page 579 BO–28 BODY – FRONT DOOR FRONT DOOR ASSEMBLY 1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE (a) Apply MP grease to the window regulator rollers. (b) Apply MP grease to the sliding surface of the door lock. 2. INSTALL DOOR LOCK CYLINDER Install the lock cylinder with the bolt to the outside handle.
Page 580 BO–29 BODY – FRONT DOOR 3. INSTALL OUTSIDE HANDLE (a) Install the outside handle with 2 bolts. (b) Install hole plug. 4. INSTALL DOOR LOCK (a) Apply adhesive to 3 screws. Part No.08833–00070, THREE BOND 1324 or equivalent (b) Install the lock with 3 screws. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) (c) w/ Power Door Lock: Connect the connector.
Page 581 BO–30 BODY – FRONT DOOR 8. Sedan, Wagon: INSTALL DOOR INSIDE PANEL (a) Install the frame with the 3 bolts. (b) Install the 4 nuts. Torque: 5.4 N–m (55 kgf–cm, 48in.–lbf) 9. INSTALL FRONT DOOR WEATHERSTRIP Push down on the clips of the weatherstrip. 10.
Page 582 BO–31 BODY – FRONT DOOR 15. ADJUST DOOR GLASS Adjust the glass and tighten when dimension A and B, as shown, are equal. HINT: Substitute the bolt with washer for the center– ing bolt. 16. INSTALL SERVICE HOLE COVER Seal the service hole cover with adhesive. HINT: Bring out the links through the service hole cover.
Page 583 BO–32 BODY – FRONT DOOR (f) Insert the upper edge of the trim from above, tap the trim by hand, fix it in place with the clips, then connect the connectors. (g) Install the 6 screws. (h) Install the 2 screw caps and the tweeter cover. (i) Install the 2 clips.
Page 584 BO–33 BODY – FRONT DOOR 23. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with the snap ring, as shown.
Page 585 BO–34 BODY – REAR DOOR REAR DOOR COMPONENTS...
Page 586 BO–35 BODY – REAR DOOR COMPONENTS (Cont’d)
Page 587 BO–36 BODY – REAR DOOR REAR DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS (a) Remove rear seat cushion and rear seat back. (b) Sedan: Remove roof side inner garnish. (c) Sedan: Remove rear seat side garnish. (d) Sedan: Remove front door inside scuff plate.
Page 588 BO–37 BODY – REAR DOOR 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute the bolt with washer for the center– ing bolt. 3. ADJUST DOOR LOCK STRIKER (a) Check that the door fit and door lock linkages are adjusted correctly.
Page 589 BO–38 BODY – REAR DOOR 4. REMOVE DOOR TRIM HINT: Tape the screwdriver tip before use. (a) Remove 4 clips. (b) Using a screwdriver, remove the screw cap. (c) Remove 2 screws. (d) Insert the screwdriver between the door and the door trim to pry out.
Page 590 BO–39 BODY – REAR DOOR 8. REMOVE REAR DOOR BELT MOULDING Pry out the clips from the edge of the weatherstrip and remove the moulding. 8. Sedan: REMOVE DOOR GLASS DIVISION BAR (a) Remove the screw. (b) Remove 2 bolts and the division bar. 10.
Page 591 BO–40 BODY – REAR DOOR 13. Wagon: REMOVE REAR DOOR FRAME MOULDING (a) Remove 2 screws and nut. (b) Pry out the clips and remove the moulding. 14. REMOVE REAR DOOR FRAME MOULDING (a) Remove 3 screws. (b) Pry out the clips and remove the moulding. 15.
Page 592 BO–41 BODY – REAR DOOR 17. REMOVE DOOR INSIDE PANEL FRAME (a) Remove 4 nuts. (b) Remove 3 bolts and the frame. 18. REMOVE WINDOW REGULATOR (a) Remove 2 nuts. (b) w/ Power Window: Disconnect the connector. (c) Remove the regulator through the service hole. 19.
Page 593 BO–42 BODY – REAR DOOR POWER WINDOW MOTOR REMOVAL AND INSTALLATION 1. REMOVE POWER WINDOW MOTOR (a) Remove the cover plate by bending its tabs. (b) Pull out the drum while detaching the cable guide out from the motor. HINT: Pull out the drum and the cable guide evenly without tilting the drum.
Page 594 BO–43 BODY – REAR DOOR (b) Attach the compression spring onto the cable. (c) Attach the cable onto the cable guide. (d) Attach the cable onto the drum. HINT: Do not cross the cable ends. (e) Wrap the cable around the drum from the top. (f) Wrap the cable around the drum from the bottom.
Page 595 BO–44 BODY – REAR DOOR REAR DOOR ASSEMBLY 1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE (a) Apply MP grease to the window regulator rollers. (b) Apply MP grease to the sliding surface of the door lock. 2. INSTALL OUTSIDE HANDLE Install the outside handle with 2 bolts.
Page 596 BO–45 BODY – REAR DOOR 6. INSTALL DOOR INSIDE PANEL FRAME (a) Install the frame with 3 bolts. (b) Install 4 nuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) 7. INSTALL REAR DOOR WEATHERSTRIP Push down on the clips of the weatherstrip. 8.
Page 597 BO–46 BODY – REAR DOOR 12. INSTALL DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Insert the glass to the frame. (b) Temporarily tighten 2 glass mounting bolts. 13. Sedan: INSTALL DOOR GLASS DIVISION BAR Install the division bar with 2 bolts and the screw.
Page 598 BO–47 BODY – REAR DOOR 18. INSTALL SERVICE HOLE COVER (a) Seal the service hole cover with adhesive. HINT: Bring out the links through the service hole cover. (b) w/ Power Window: Install 2 screw grommets. (c) w/o Power Window: Install 3 screw grommets.
Page 599 BO–48 BODY – REAR DOOR 23. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with the snap ring, as shown.
Page 600 BO–49 BODY – BACK DOOR BACK DOOR COMPONENTS...
Page 601 BO–50 BODY – BACK DOOR BACK DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD / REARWARD AND LEFT /RIGHT DIRECTIONS (a) Remove the rear header trim. (b) Loosen the body side hinge nuts to adjust. Torque: 13 N–m (130 kgf–cm, 9.4 ft–lbf) (c) Install the rear header trim.
Page 602 BO–51 BODY – BACK DOOR BACK DOOR DAMPER STAY NOTICE: Handling the damper. Do not disassemble the damper because the cylinder is filled with pressurized gas. If the damper is to be replaced, drill a 2.0 – 3.0 mm (0.079 – 0.118 in.) hole in the bottom of the re– moved damper cylinder to completely release the high–pressure gas before disposing of it.
Page 603 BO–52 BODY – BACK DOOR (e) Back door trim cover RH (f) Back door inside handle bezel (g) Speaker cover and speaker (h) Back door trim board (i) Wiper motor and link (j) License plate light (k) Back door outside garnish (1) Back door outside handle (m) Rear combination lights (n) Back door control...
Page 604 BO–53 BODY – LUGGAGE COMPARTMENT LUGGAGE COMPARTMENT COMPONENTS...
Page 605 BO–54 BODY – LUGGAGE COMPARTMENT LUGGAGE COMPARTMENT DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND LEFT/RIGHT DIRECTIONS (a) Remove rear seat cushion and rear seat back. (b) Remove roof side inner garnish. (c) Remove package tray trim garnish. (d) Remove package tray trim. (e) Loosen 2 body side hinge bolt to adjust.
Page 606 BO–55 BODY – LUGGAGE COMPARTMENT TORSION BAR REMOVAL AND INSTALLATION 1. REMOVE FOLLOWING PARTS: (a) Rear floor finish plate (b) Rear luggage trim (c) Right side luggage trim (d) Left side luggage trim 2. REMOVE TORSION BAR (a) Remove the torsion bar from center bracket. (b) Install SST to the torsion bar on the hinge side.
Page 607 BO–56 BODY – LUGGAGE COMPARTMENT (b) Install SST to the torsion bar of the hinge side. SST 09804–24010 (c) Slowly lift the torsion bar with SST and place in the torsion bar bracket. (d) Slowly push down SST, and install the torsion bar to the hinge.
Page 608 BO–57 BODY – WIPER AND WASHER WIPER AND WASHER COMPONENTS...
Page 609 BO–58 BODY – WIPER AND WASHER COMPONENTS (Cont’d)
Page 610 BO–59 BODY – WIPER AND WASHER WIPER AND WASHER REMOVAL 1. REMOVE WIPER ARMS Remove 2 nuts and 2 wiper arms. 2. REMOVE COWL LOUVER (a) Using a clip remover, remove the clips and the weath– erstrip. (b) Pull out the cowl louver forwards as shown. 3.
Page 611 BO–60 BODY – WIPER AND WASHER WIPER AND WASHER INSTALLATION INSTALL FOLLOWING PARTS: (a) Window washer nozzle (b) Wiper link (c) Wiper motor (d) Wiper arms Torque: 19 N–m (195 kgf–cm. 14 ft–lbf) REAR WIPER REMOVAL 1. REMOVE,REAR WIPER ARMS (a) Remove 2 ’nuts and 2 wiper arms.
Page 612 BO–61 BODY – WIPER AND WASHER REAR WIPER INSTALLATION ASSEMBLE REAR WIPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE INSTALL REAR WIPER ARM (a) Install 2 washers with 2 nuts. Torque: 11 N .m (110 kgf–cm, 8 ft–Ibf) (b) Install the wiper arm and operate the wiper once and turn the wiper switch OFF.
Page 613 BO–62 BODY – WINDSHIELD MOULDING WINDSHIELD MOULDING COMPONENTS WINDSHIELD MOULDING REMOVAL 1. REMOVE WEATHERSTRIP Remove the weatherstrip by pulling. 2. REMOVE WINDSHIELD OUTSIDE MOULDING Remove 3 screws and the moulding.
Page 614 BO–63 BODY – WINDSHIELD MOULDING 3. REMOVE WINDOWSHIELD UPPER MOULDING (a) Insert the top of scraper between the body and the moulding. HINT: Tape the scraper tip before use. (b) Pry up the scraper to loosen the moulding from the claws of the clips and retainers.
Page 615 BO–64 BODY – BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING COMPONENTS...
Page 616 BO–65 BODY – BODY OUTSIDE MOULDING FRONT DOOR BELT AND FRAME MOULDING REMOVAL AND INSTALLATION 1. REMOVE FRONT DOOR COMPONENT PARTS (See steps 1 to 5 and 9 pages BO–23 to 25) 2. REMOVE FRONT DOOR BELT MOULDING (See step 10 on page BO–25) 3.
Page 617 BO–66 BODY – BODY OUTSIDE MOULDING SIDE PROTECTION MOULDING REMOVAL Precautions for storing moulding material: Store in a cool place, avoiding direct sunlight, high temperature and dust. The moulding is of polyvinyl chloride, so do not allow it to come in contact with thinner or other solvents, open flame, or boiling water.
Page 618 BO–67 BODY – BODY OUTSIDE MOULDING 3. HEAT MOULDING Using a heat light, heat the moulding to 20 – 30_ C (68_– 86_ F) NOTICE: Do not heat moulding excessively. The temperature should not be higher than 80 C (176 4.
Page 619 BO–68 BODY – BODY OUTSIDE MOULDING OUTSIDE LOWER MOULDING REMOVAL AND INSTALLATION 1. REMOVE FRONT FENDER LOWER MOULDING (a) Remove the screw. (b) Pry out the clip and remove the moulding. 2. REMOVE FRONT DOOR LOWER MOULDING (a) Remove 2 hole plugs. (b) Remove 2 nuts.
Page 620 BO–69 BODY – BODY OUTSIDE MOULDING 2. REMOVE REAR DOOR BELT MOULDING Pry out the clips from the edge of the weatherstrip and remove the moulding. 3. REMOVE REAR DOOR REAR FRAME MOULDING (a) Remove 2 screws and the nut. (b) Pry out the clips and remove the moulding.
Page 621 BO–70 BODY – BODY OUTSIDE MOULDING QUARTER WINDOW MOULDING REMOVAL AND INSTALLATION 1. REMOVE QUARTER WINDOW FRONT MOULDING Pry out the clips and remove the moulding. 2. REMOVE QUARTER WINDOW UPPER MOULDING Pry out the clips and remove the moulding. 3.
Page 622 BO–71 BODY – BACK WINDOW MOULDING BACK WINDOW MOULDING COMPONENTS BACK WINDOW MOULDING REMOVAL 1. REMOVE BACK WINDOW LOWER MOULDING Using a scraper, pry off the moulding from the clips and remove the moulding. HINT: Tape the scraper tip before use. 2.
Page 623 BO–72 BODY – BACK WINDOW MOULDING BACK WINDOW MOULDING INSTALLATION 1. CUT ADHESIVE AT MOULDING INSTALLATION AREA Using the knife, cut off the adhesive around the mou– Iding installation area. 2. APPLY ADHESIVE AT MOULDING INSTALLATION AREA 3. INSTALL BACK WINDOW MOULDING Place the moulding onto the body and tap it by hand.
Page 624 BO–73 BODY – BACK DOOR MOULDING BACK DOOR MOULDING COMPONENTS...
Page 625 BO–74 BODY – BACK DOOR MOULDING BACK DOOR MOULDING REMOVAL REMOVE BACK DOOR MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. BACK DOOR MOULDING INSTALLATION 1. CUT ADHESIVE AT MOULDING INSTALLATION AREA Using the knife, cut off the adhesive around the mou–...
Page 626 BO–75 BODY – WINDSHIELD WINDSHIELD COMPONENTS...
Page 627 BO–76 BODY – WINDSHIELD WINDSHIELD REMOVAL 1. REMOVE FOLLOWING PARTS: (a) Inner rear view mirror (b) Sunvisors and holders (c) Front assist grip (d) Interior light 2. REMOVE FRONT PILLAR GARNISH (a) Sedan, Wagon: Remove the clips by your hand. (b) Sedan, Wagon: Pull the garnish rearwards to remove (c) Coupe: Rear side garnish must be removed before front piller garnish.
Page 628 BO–77 BODY – WINDSHIELD 8. REMOVE WINDSHIELD GLASS (a) Push piano wire through from the interior. (b) Tie both wire ends to a wooden block or like object_ HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and interior and exterior ornaments.
Page 629 BO–78 BODY – WINDSHIELD 4. INSTALL RETAINER Install the retainers as shown. 5. INSTALL SPACER 6. POSITION GLASS (a) Place glass in correct position. (b) Check that all contacting parts of the glass rim are perfectly even and do not make contact with the fasteners.
Page 630 BO–79 BODY – WINDSHIELD 9. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M. NOTICE: Let the primer coating dry for 3 minutes or more. Do not coat to the adhesive. Do not keep any of the opened primer M and G for later use.
Page 631 BO–80 BODY – WINDSHIELD (d) Coat the body with adhesive as shown. 13. INSTALL GLASS HINT: Confirm that the dam is attached the body panel as shown in the illustration. (a) Position the glass so that the reference marks are lined up, and press in gently along the rim.
Page 632 BO–81 BODY – WINDSHIELD 14. INSPECT FOR LEAKS AND REPAIR (a) Perform a leak test after the hardening time has ela– psed. (b) Seal any leak with auto glass sealer. Part No. 08833–00030 15. INSTALL WINDSHIELD UPPER MOULDING (a) Place the moulding onto the body. (b) Tap the moulding with your hand to fasten the clips at the glass edge.
Page 633 BO–82 BODY – BACK WINDOW GLASS BACK WINDOW GLASS COMPONENTS...
Page 634 BO–83 BODY – BACK WINDOW GLASS BACK WINDOW GLASS REMOVAL 1. REMOVE REAR SEAT CUSHION AND SEAT BACK 2. REMOVE ROOF SIDE INNER GARNISH (a) Remove the clips. (b) Remove the garnish by pulling. 3. w/o Rear Spoiler: REMOVE HIGH MOUNT STOP LIGHT (a) Remove the cover.
Page 635 BO–84 BODY – BACK WINDOW GLASS 9. REMOVE BACK WINDOW MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. 10. REMOVE BACK WINDOW GLASS Remove the glass in the same manner as windshield. (See step 8 on page BO–77) 11.
Page 636 BO–85 BODY – BACK WINDOW GLASS 9. COAT CONTACT SURFACE OF GLASS WITH PRIMER ’G” (SEE STEP 10 ON PAGE BO–79) 10. MIX ADHESIVE COATING (SEE STEP 11 ON PAGE BO–79) 11. APPLY ADHESIVE (SEE STEP 12 ON PAGE BO–79) 12.
Page 637 BO–86 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS COMPONENTS...
Page 638 BO–87 BODY – QUARTER WINDOW GLASS COMPONENTS (Cont’d)
Page 639 BO–88 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS REMOVAL Coupe: 1. REMOVE REAR SEAT CUSHION 2. REAR SIDE SEAT BACK 3. REMOVE FOLLOWING PARTS: (a) Front seat outer belt shoulder anchor (b) Front seat outer belt bezel (c) Rear seat outer belt anchor (d) Roof side inner garnish.
Page 640 BO–89 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS REMOVAL Wagon: 1. REMOVE REAR HEADER TRIM Remove the trim by pulling, then disconnect the con– nector. 2. REMOVE REAR FLOOR FINISH PLATE (a) Remove 2 cushions. (b) Remove 6 covers and 6 screws. (c) Remove the plate.
Page 641 BO–90 BODY – QUARTER WINDOW GLASS (e) w/ Third Seat: Deck side rear garnish (f) Roof side inner garnish RH Left Side: (a) Rear side seatback LH (b) Tonneau side cover LH (c) Deck trim side panel LH (d) Roof side inner garnish LH...
Page 642 BO–91 BODY – QUARTER WINDOW GLASS 4. REMOVE QUARTER WINDOW FRONT MOULDING Pry out the clips and remove the moulding. 5. REMOVE QUARTER WINDOW UPPER MOULDING Pry out the clips and remove the moulding. 6. REMOVE QUARTER WINDOW REAR MOULDING Pry out the clips and remove the moulding.
Page 643 BO–92 BODY – QUARTER WINDOW GLASS 3. INSTALL FOLLOWING PARTS: (a) Front door weatherstrip. (b) Quarter trim board (c) Front door scuff plate (d) Roof side inner garnish (e) Rear seat outer belt anchor Torque: 43 N–m (440 kgf–cm. 32 ft–lbf) (f) Front seat outer belt bezel (g) Front seat outer belt shoulder anchor Torque: 43 N–m (440 kgf–cm, 32 ft–lbf)
Page 644 BO–93 BODY – QUARTER WINDOW GLASS (b) w/ Third Seat: Deck side rear garnish (c) Deck trim side panel RH (d) Tonneau side cover RH (e) w/ Third Seat: Spare wheel cover (f) Rear side seatback RH Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) Left Side: (a) Roof side inner garnish LH (b) Deck trim side panel LH...
Page 645 BO–94 BODY – BACK DOOR GLASS BACK DOOR GLASS COMPONENTS...
Page 646 BO–95 BODY – BACK DOOR GLASS BACK DOOR GLASS REMOVAL 1. REMOVE FOLLOWING PARTS: (a) Back door trim upper board (b) w/ High Mount Stop Light: High mount stop light (c) Back door trim cover LH (d) Back door trim cover RH 2.
Page 647 BO–96 BODY – BACK DOOR GLASS BACK DOOR GLASS INSTALLATION HINT: Install the glass in the same manner as the windshield. 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY 2. CLEAN REMOVED GLASS 3. POSITION GLASS 4. CLEAN CONTACT SURFACE OF GLASS 5.
Page 648 BO–97 BODY – SLIDING ROOF SLIDING ROOF COMPONENTS...
Page 649 BO–98 BODY – SLIDING ROOF ON–VEHICLE INSPECTION INSPECT SLIDING ROOF GLASS ALIGNMENT (a) Start the engine and check the operation time of the sliding roof. Operation time: Approx.6 sacs. (b) Check for abnormal noise or binding during operation. (c) With the sliding roof fully closed, check for water leakage.
Page 650 BO–99 BODY – SLIDING ROOF 3. TO ADJUST FORWARD OR REARWARD (a) Adjust by loosening the sliding roof installation nuts, and move the sliding roof bracket forwards and back– wards. (b) When the front or rear alignment is not correct, remove the glass and adjust the drive rail.
Page 651 BO–100 BODY – SLIDING ROOF Adjust by loosening the sliding roof installation nuts and readjust the sliding roof to the proper position. SLIDING ROOF REMOVAL 1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL CAUTION: Work must be started after. 90 seconds from the time the ignition switch is turned to the ”LOCK”...
Page 652 BO–101 BODY – SLIDING ROOF 6. REMOVE SLIDING ROOF CONTROL RELAY (a) Disconnect the connector. (b) Remove the bolt, the connector and the relay. 7. REMOVE DRIVE GEAR (a) Disconnect the connectors. (b) Remove 3 bolts and the drive gear. 8.
Page 653 BO–102 BODY – SLIDING ROOF 11. REMOVE ROOF DRIP CHANNEL (a) Remove 2 screws. (b) Pull the channel forwards to remove it. 12. REMOVE WIND DEFLECTOR PANEL (a) Slide the drive cable backwards. (b) Remove 4 screws and the panel. 13.
Page 654 BO–103 BODY – SLIDING ROOF SLIDING ROOF DISASSEMBLY 1. REMOVE SLIDING ROOF PANEL STOPPER Remove the screw and the stopper. 2. REMOVE SUNSHADE TRIM Pull the trim rearwards to remove it. 3. REMOVE CABLE GUIDE CASING Remove 2 screws and the casing. 4.
Page 655 BO–104 BODY – SLIDING ROOF SLIDING ROOF ASSEMBLY 1. INSTALL DRIVE CABLE (a) Insert the drive cable to the drive rail. (b) Install the cable guide block with 2 screws. 2. INSTALL SLIDING ROOF FRONT STOPPER Install the stopper with the screw. 3.
Page 656 BO–105 BODY – SLIDING ROOF SLIDING ROOF INSTALLATION 1. INSTALL CABLE GUIDE CASING ASSEMBLY (a) Apply adhesive tape to protect the body. (b) Push the cable guide casing assembly rearwards to remove it. (c) Install 11 screws. 2. INSTALL WIND DEFLECTOR PANEL Install the panel with 4 screws.
Page 657 BO–106 BODY – SLIDING ROOF 4. INSTALL ROOF DRIP CHANNEL (a) Push the channel rearwards to install it. (b) Install 2 screws. 5. INSTALL FRONT AND REAR GARNISH Tap the garnishes to install it. 6. INSTALL SLIDING ROOF GLASS Install the glass and the shims with 6 nuts. 7.
Page 658 BO–107 BODY – SLIDING ROOF 8. INSTALL SLIDING ROOF CONTROL RELAY (a) Install the relay with the bolt. (6) Connect the connector. 9. INSTALL FRONT SIDE OF ROOF HEADLINING Connect the front side of roof headlining to the front side of housing. 10.
Page 659 BO–108 BODY – INSTRUMENT PANEL INSTRUMENT PANEL COMPONENTS...
Page 660 BO–109 BODY – INSTRUMENT PANEL COMPONENTS (Cont’d)
Page 661 BO–110 BODY – INSTRUMENT PANEL HINT: Screw sizes in the illustration on the previous page are indicated using the code below for removal and installation of instrument panel. INSTRUMENT PANEL REMOVAL 1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’...
Page 662 BO–111 BODY – INSTRUMENT PANEL (b) Sedan, Wagon: Pull the garnish rearwards to remove (e) Coupe: Rear side garnish must ba removed before front piller garnish. 3. REMOVE FRONT DOOR INSIDE SCUFF PLATE Remove the scuff plate by pulling. 4. REMOVE FRONT DOOR OPENING COVER Remove the cover by pulling.
Page 663 BO–112 BODY – INSTRUMENT PANEL 6. REMOVE COWL SIDE TRIM (a) Remove the clip. (b) Remove the trim by pulling. 7. REMOVE STEERING WHEEL (See page SR–5) 8. REMOVE STEERING COLUMN COVER Remove 5 screws and the covers. 9. REMOVE CONSOLE UPPER PANEL Using a screwdriver, remove the panel then discon–...
Page 664 BO–113 BODY – INSTRUMENT PANEL 12. REMOVE INSTRUMENT PANEL LOWER PAD (a) Remove 2 screws and the coin box bezel. (b) Remove 4 bolts, the screw and the lower pad. 13. REMOVE COMBINATION SWITCH (a) Disconnect the connectors. (b) Remove 4 screws and the combination switch. 14.
Page 665 BO–114 BODY – INSTRUMENT PANEL 17. REMOVE GLOVE COMPARTMENT DOOR Remove 3 nuts and the door. 18. REMOVE GLOVE COMPARTMENT HINT: Tape a screwdriver tip before use. (a) Remove the glove compartment door finish plate inside the instrument panel box. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness.
Page 666 BO–115 BODY – INSTRUMENT PANEL 21. REMOVE REGISTER NO. 1 AND NO. 2 (a) Remove 2 screws and the register No.1. (b) Remove 2 screws and the register No.2. 22. REMOVE RADIO Remove 4 bolts and the radio, then disconnect the connectors.
Page 667 BO–116 BODY – INSTRUMENT PANEL 25. REMOVE DUCT HEATER TO REGISTER NO. 2 Remove the clip and the register No.2. 26. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Remove the LH side installation bolt. (b) Remove 5 bolts and 2 clips. CAUTION: Do not store the front passenger airbag assembly with the airbag door facing down.
Page 668 BO–117 BODY – INSTRUMENT PANEL (d) Disconnect the connectors. (e) Remove the bolt. (f) Remove the connector holder. (g) Disconnect the connector. (h) Remove the bolt. (i) Remove 8 bolts, 2 nuts and the instrument panel. (j) Remove the duct heater to register No.4 and No.5.
Page 669 BO–118 BODY – INSTRUMENT PANEL 29. REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the parts as shown below. INSTRUMENT PANEL DISASSEMBLY 1. REMOVE FOLLOWING PARTS FROM INSTRUMENT PANEL (a) Duct heater to register No.1 (b) Duct heater to register No.3 (c) Defroster nozzle (d) Register No.3 (e) Center bracket (f) Mounting bracket No.1...
Page 670 BO–119 BODY – INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY ASSEMBLE INSTRUMENT PANEL PARTS BY FOLLOW– ING DISASSEMBLY SEQUENCE IN REVERSE INSTRUMENT PANEL INSTALLATION INSTALL INSTRUMENT PANEL PARTS BY FOLLOWING REMOVAL SEQUENCE IN REVERSE TORQUE FOLLOWING BOLTS: Front passenger airbag assembly (See page RS–34) To instrument panel reinforcement Torque: 20 N–m (210 kgf–cm, 15 ft–lbf) To instrument panel...
Page 671 BO–120 BODY – SEAT SEAT COMPONENTS...
Page 672 BO–121 BODY – SEAT COMPONENTS (Cont’d)
Page 673 BO–122 BODY – SEAT COMPONENTS (Cont’d)
Page 674 BO–123 BODY – SEAT COMPONENTS (Cont’d)
Page 675 BO–124 BODY – SEAT COMPONENTS (Cont’d)
Page 676 BO–125 BODY – SEAT COMPONENTS (Cont’d)
Page 677 BO–126 BODY – SEAT COMPONENTS (Cont’d)
Page 678 BO–127 BODY – SEAT BELT SEAT BELT COMPONENTS...
Page 679 BO–128 BODY – SEAT BELT COMPONENTS (Cont’d)
Page 680 BO–129 BODY – SEAT BELT COMPONENTS (Cont’d)
Page 681 BO–130 BODY – SEAT BELT COMPONENTS (Cont’d)
Page 682 BO–131 BODY – SEAT BELT COMPONENTS (Cont’d)
Page 683 BO–132 BODY – SEAT BELT COMPONENTS (Cont’d)
Page 684 BO–133 BODY – SEAT BELT SEAT BELT INSPECTION Emergency Locking Retractor (ELR) and Automatic Locking Retractor (ALR) type 1. RUNNING TEST (INN SAFE AREA) for all seat: (a) Fasten the front seat belts. (b) Drive the car at 10 mph (16 km/h) and make a very hard stop.
Page 685 BO–134 BODY – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened FRONT BUMPER Front bumper arm x Body Front bumper reinforcement x Front bumper arm Reinforcement extension x Body REAR BUMPER Rear bumper arm x Body Rear bumper reinforcement x Rear bumper arm Rear bumper cover x Body HOOD.
Page 686 BO–135 BODY – SERVICE SPECIFICATIONS Bracket x Body SEAT BELT Front Seat Belt Shoulder anchor x Adjustable anchor Outer belt anchor x Body ELR x Body Adjustable anchor x Body Inner belt x Seat Rear Seat Belt Shoulder anchor x Body Outer belt anchor x Body ELR x Body Inner belt x Body...
Page 687 BR–1 BRAKE SYSTEM – BRAKE SYSTEM...
Page 688 BR–2 BRAKE SYSTEM – GENERAL DESCRIPTION GENERAL DESCRIPTION 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent.
Page 689 BR–3 BRAKE SYSTEM – OPERATION OPERATION FOOT BRAKE when the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the cylinder.
Page 690 BR–4 BRAKE SYSTEM – OPERATION PARKING BRAKE Rear Drum Brake: When the parking brake lever is pulled, the parking brake shoe lever is pulled via the parking brake wire. This causes the adjuster to push the front shoe, which expands and is pressed against the brake drum.
Page 691 BR–5 BRAKE SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09023–00100 Union Nut Wrench 10 mm 09703–30010 Brake Shoe Return Spring Tool LSPV Gauge Set 09709–29017 09718–00010 Shoe Hold Down Spring Driver 09737–00010 Brake Booster Push Rod Gauge 09751–36011 Brake Tube Union Nut 10 x 12 mm Wrench 09843–18020 Diagnosis Check Wire TMC made vehicle...
Page 692 BR–6 BRAKE SYSTEM – PREPARATION RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09905–00013 Snap Ring Pliers EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Vernier calipers Brake drum and disc LUBRICANT Item Capacity Classification Brake fluid SAE J 1703 or FMVSS No. 116 DOT3...
Page 693 BR–7 BRAKE SYSTEM – TROUBLESHOOTING TROUBLESHOOTING !M19–0F Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. See page Part Name (Trouble)
Page 694 BR–8 BRAKE SYSTEM – CHECK AND ADJUSTMENT CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMEN 1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: 147.5–157.5 mm (5.81–6.20 fn.) If the pedal height is incorrect, adjust it. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch.
Page 695 BR–9 BRAKE SYSTEM – CHECK AND ADJUSTMENT 4. CHECK THAT PEDAL RESERVE DISTANCE IS COR– RECT Release the parking brake. With the engine running, depress the pedal and meas– ure the pedal reserve distance. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 70 mm (2.76 in.) If the reserve distance is incorrect, troubleshoot the...
Page 696 BR–10 BRAKE SYSTEM – CHECK AND ADJUSTMENT (c) Block off the outer holes with your fingers, and re– lease the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the brake caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down.
Page 697 BR–11 BRAKE SYSTEM – CHECK AND ADJUSTMENT (c) Tighten the lock nut. Torque: 5.4 N–m (55 kgf–cm. 48 in.¿lbf) (d) Install the rear console box. PEDAL TYPE PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK THAT PARKING BRAKE PEDAL TRAVEL IS CORRECT Slowly depress the parking brake pedal all the way, and count the number of clicks.
Page 698 BR–12 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNEC – TOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted sur– face. Wash it off immediately. 3.
Page 699 BR–13 BRAKE SYSTEM – MASTER CYLINDER COMPONENTS...
Page 700 BR–14 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. 2. REMOVE RESERVOIR (a) Remove the set screw and pull out the reservoir. (b) Remove the cap and strainer from the reservoir. 3.
Page 701 BR–15 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. MASTER CYLINDER ASSEMBLY 1.
Page 702 BR–16 BRAKE SYSTEM – MASTER CYLINDER 4. INSTALL 2 GROMMETS 5. INSTALL RESERVOIR (a) Install the strainer and cap to the reservoir. (b) Push the reservoir onto the cylinder. (c) Install the set screw while pushing on the reservoir. Torque: 1.7 N–m (17.5 kgf–cm, 15.2 in.–lbf) 6.
Page 703 BR–17 BRAKE SYSTEM – MASTER CYLINDER 3. CONNECT 2 BRAKE LINES Using SST, connect the brake lines to the master cylinder_ Torque the union nuts. SST 09023–00100 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. CONNECT LEVEL WARNING SWITCH CONNECTOR 5.
Page 704 BR–18 BRAKE SYSTEM – BRAKE BOOSTER BRAKE BOOSTER BRAKE BOOSTER REMOVAL 1. REMOVE MASTER CYLINDER (See page BR–12) 2. PUSH DOWN CHARCOAL CANISTER Loosen the clamp screw and push the charcoal canis– ter down slightly.
Page 705 BR–19 BRAKE SYSTEM – BRAKE BOOSTER 3. DISCONNECT VACUUM HOSE FROM BRAKE BOO– STER 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND CLEVIS PIN 6. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS (a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket. BRAKE BOOSTER INSTALLATION 1.
Page 706 BR–20 BRAKE SYSTEM – BRAKE BOOSTER 8. CHECK AND ADJUST BRAKE PEDAL (See page BR–8) Check and adjust the brake pedal, then tighten the clevis lock nut. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) 9. PERFORM OPERATIONAL CHECK (See page BR–9)
Page 707 BR–21 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE (Single–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts.
Page 708 BR–22 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt.
Page 709 BR–23 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) 1 MZ–FE engine: Install a pad wear indicator plate on the inside pad. (b) Apply disc brake grease to both sides of the inner anti –squeal shim.
Page 710 BR–24 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1.
Page 711 BR–25 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed sir.
Page 712 BR–26 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine 12.0 mm (0.472 In.) 1 MZ–FE engine 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini–...
Page 713 BR–27 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020in.), install the disc in that position.
Page 714 BR–28 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SET RING CALIPER INSTALLATION 1. INSTALL 2 BRAKE PADS Install the inside and outside pads. 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts.
Page 715 BR–29 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) FRONT BRAKE (2–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts.
Page 716 BR–30 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt.
Page 717 BR–31 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 7. INSTALL NEW PADS (a) Install the pad wear indicator plate on the pad. (b) Apply disc brake grease to both sides of the inner anti–squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) Install the inner pad with the pad wear indicator plates facing upward.
Page 718 BR–32 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads with anti–squeal shims (c) 4 pad support plates CALIPER DISASSEMBLY...
Page 719 BR–33 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1.
Page 720 BR–34 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub.
Page 721 BR–35 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket and a hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.
Page 722 BR–36 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 26 ft–lbf) 3.
Page 723 BR–37 BRAKE SYSTEM – REAR BRAKE(Drum Brake) REAR BRAKE (Drum Brake) COMPONENTS REAR DRUM BRAKE REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2.
Page 724 BR–38 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. REMOVE FRONT SHOE (a) Using SST, disconnect the return spring. SST 09703–30010 (b) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (c) Disconnect the anchor spring from the front shoe and remove the front shoe.
Page 725 BR–39 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 8. REMOVE WHEEL CYLINDER Remove the 2 bolts and the wheel cylinder. 9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder. 2 boots 2 pistons 2 piston cups Spring REAR DRUM BRAKE COMPONENTS INSPECTION AND REPAIR...
Page 726 BR–40 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. REAR DRUM BRAKE INSTALLATION HINT: Assemble the parts in the correct direction as shown.
Page 727 BR–41 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 3. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. APPLY HIGH TEMPERATURE GREASE TO BACK – ING PLATE AND ADJUSTER (a) Apply high temperature grease to the brake shoe contact surfaces.
Page 728 BR–42 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (d) Using SST, install the shoe hold–down spring, cups and pin. SST 09718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL FRONT SHOE (a) Install the anchor spring between the front and rear shoes.
Page 729 BR–43 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (c) Align the adjusting hole on the brake drum and largest hole on the axle carrier, install the brake drum. (d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard. 9.
Page 730 BR–44 BRAKE SYSTEM – REAR BRAKE(Disc Brake) REAR BRAKE (Disc Brake) COMPONENTS...
Page 731 BR–45 BRAKE SYSTEM – REAR BRAKE(Disc Brake) BRAKE PADS REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) 3.
Page 732 BR–46 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 4 anti–squeal shims (c) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–50) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7.
Page 733 BR–47 BRAKE SYSTEM – REAR BRAKE(Disc Brake) (c) Install the caliper and torque the installation bolt. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (d) Install the flexible hose bracket. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 9. INSTALL REAR WHEEL 14.
Page 734 BR–48 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. REMOVE 2 PADS Remove the inside and outside pads. 4. REMOVE MAIN PIN Loosen the. main pin installation bolt and remove the main pin. CALIPER DISASSEMBLY 1. REMOVE SLIDING BUSHING Pull out the sliding bushing. 2.
Page 735 BR–49 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. 5. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper.
Page 736 BR–50 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less.
Page 737 BR–51 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. INSTALL CYLINDER BOOT AND SET RING IN CYL– INDER 4. INSTALL DUST BOOTS (a) Place the caliper in vise. (b) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (c) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.
Page 738 BR–52 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. INSTALL 2 PADS Install 2 pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 3.
Page 739 BR–53 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) REAR BRAKE (Parking Brake for Rear Disc Brake) COMPONENTS PARKING BRAKE DISASSEMBLY 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE ASSEMBLY (a) Remove the 2 mounting bolts and remove the disc brake assembly.
Page 740 BR–54 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 4. REMOVE SHOE RETURN SPRINGS Using needle–nose pliers, remove the shoe return springs. 5. REMOVE FRONT SHOE, ADJUSTER AND TENSION SPRING (a) Slide out the front shoe and remove the shoe adjuster. (b) Remove the shoe strut with the spring.
Page 741 BR–55 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 2. MEASURE BRAKE SHOE LINING THICKNESS Using a scale, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is excessively uneven wear, replace the brake shoe.
Page 742 BR–56 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 6. IF NECESSARY, REPLACE SHIM (a) Remove the parking brake lever, and install the cor– rect size shim. (b) Install the parking brake lever with a new C–washer. (c) Remeasure the clearance. PARKING BRAKE ASSEMBLY HINT: Assemble the parts in the correct direction as shown.
Page 743 BR–57 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 1. APPLY HIGH TEMPERATURE GREASE ON BACK– ING PLATE 2. APPLY HIGH TEMPERATURE GREASE TO ADJUSTER 3. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER (a) Install the shoe hold–down springs, cups and pins. (b) Using needle–nose pliers, connect the parking brake cable to the parking brake lever.
Page 744 BR–58 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) (d) Install the shoe strut with the spring. (e) Slide in the front shoe between the shoe hold–down spring cup and the backing plate. 6. INSTALL SHOE RETURN SPRINGS Using needle–nose pliers, install the shoe return spr–...
Page 745 BR–59 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 9. INSTALL DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mot nting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) 10. INSTALL REAR WHEEL 11. SETTLING PARKING BRAKE SHOES AND DISC (a) LEVER TYPE: With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbf) of force.
Page 746 BR–60 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE PARKING BRAKE PEDAL DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF PEDAL INSTALLATION INSTALL SHOCK ABSORBER (a) Loosen the union lock nut. (b) Install the shock absorber to the pin on the pedal bracket side, then extend the piston rod fully.
Page 747 BR–61 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE INTERMEDIATE LEVER DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF INTERMEDIATE LEVER INSTALLATION MEASURE CLEARANCE BETWEEN INTERMEDIATE LEVER SHAFT AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: 0.09–0.5 mm (0.004–0.02 in.) If the clearance is not within the specification, replace...
Page 748 BR–62 BRAKE SYSTEM – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) P VALVE INSPECTION 1. CONNECT FLUID PRESSURE GAUGE TO P VALVE 2. BLEED AIR FROM FLUID ’PRESSURE GAUGE 3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 5S–FE w/o ABS:...
Page 749 BR–63 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) LOAD SENSING PROPORTIONING VALVE (LSPV) COMPONENTS FLUID PRESSURE INSPECTION 1. SET REAR AXLE LOAD (a) Set the vehicle to its curb weight. (b) Measure the rear axle load and note the value. (c) Set the rear axle load.
Page 750 BR–64 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 3. RAISE FRONT BRAKE FLUID PRESSURE TO FOL– LOWING SPECIFICATION AND CHECK REAR BRAKE FLUID PRESSURE Rear brake fluid pressure: 5S–FE All, 1 MZ–FE w/ABS Front brake fluid pressure Rear brake fluid pressure kPa (kgf/cm , psi) kPa (kgf/cm...
Page 751 BR–65 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) (d) Torque the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) If it cannot be adjusted, replace the valve body. LSPV REMOVAL 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the valve body.
Page 752 BR–66 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 2. CONNECT BRAKE LINES Using SST, connect the brake lines. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 4.
Page 753 In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the ABS. An ABS actuator manufactured by BOSCH is used on the Camry produced by TMM (Toyota Motor Manufacturing U.S.A., Inc.).
Page 754 BR–68 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SYSTEM PARTS LOCATION...
Page 755 BR–69 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM TMC Made Vehicle/NIPPONDENSO ABS:...
Page 756 BR–70 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM TMM Made Vehicle/BOSCH ABS:...
Page 757 BR–71 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMC Made Vehicle/NIPPONDENSO ABS: Terminal Terminal Symbol Connection Connection Symbol Right front solenoid Left rear speed sensor Ground Right front speed sensor DLC2 DLC1, DLC2 Stop light switch ABS control (motor) relay monitor Sealed wiring harness Right rear speed sensor Left rear speed sensor...
Page 758 BR–72 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMM Made Vehicle/BOSCH ABS: Terminal Terminal Connection Symbol Connection Symbol A6S warning fight Battery Left rear speed sensor Ignition switch DLC1 Left rear speed sensor Ground Right front speed sensor Right rear speed sensor Left front speed sen- Stop light switch...
Page 759 BR–73 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMC Made Vehicle/NIPPONDENSO ABS: Symbols STD Voltage (V) Condition (Terminals No.) Always IG switch ON IG switch ON, ABS warning light OFF IG switch ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF...
Page 760 BR–74 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMM Made Vehicle/BOSCH ABS: Symbols STD Voltage (V) Condition (Terminals No.) Always IG switch ON IG switch ON, A6S warning light ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF Stop light switch OFF...
Page 761 BR–75 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMC Made Vehicle NIPPONDENSO ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown.
Page 762 BR–76 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09023–00100 Torque: 15 N–m (155 kgf–cm. 11 ft–lbf) 2.
Page 763 BR–77 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10–14.5 V 2. DISCONNECT CONNECTORS (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3.
Page 764 BR–78 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (c) Place the ”SHEET A” (SST) on the actuator checker. SST 09990–00163 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle. (b) Turn the selector switch of the actuator checker to ”FRONT RH”...
Page 765 BR–79 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (l) Turn the selector switch to ”FRONT LH” position. (m) Repeat (c) to 6), checking the actuator operation sim– ilarly. (n) Similarly, inspect ”REAR RH” and ”REAR LH” position. HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position.
Page 766 BR–80 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMM Made Vehicle BOSCH ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown.
Page 767 BR–81 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 2.
Page 768 BR–82 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown.
Page 769 BR–83 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF DISASSEMBLY AND ASSEMBLY 1. REMOVE AND INSTALL COVER Using a T15 torx wrench, loosen and tighten the screw. Torque: 1.4 N–m(14 kgf–cm, 12 in.lbf) 2. DISCONNECT AND CONNECT 4–PIN AND 6–PIN CONNECTORS NOTICE: When installing, place the 4–pin connector’s cables into the cable guide.
Page 770 BR–84 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR COMPONENTS FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor.
Page 771 BR–85 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) 2. REMOVE SPEED SENSOR (a) Remove the 3 clamp bolts holding the sensor harness to the body and shock absorber_ (b) Remove the speed sensor from the steering knuckle. FRONT SPEED SENSOR INSTALLATION ¿¿”–07 1.
Page 772 BR–86 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR COMPONENTS REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor.
Page 773 BR–87 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. (c) Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber.
Page 774 BR–88 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (b) install the grommet securely. (c) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf)
Page 775 BR–89 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) –MEMO–...
Page 776 BR–90 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMC Made Vehicle NIPPONDENSO ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 777 BR–93 Diagnostic Trouble Code Chart Problem Symptoms Chart BR–95 BR–98 Sensor Check Circuit Inspection Check for Fluid Leakage BR–108XBR–138 BR–139 Identification of Problem Repair Confirmation Test Step Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box.
Page 778 BR–92 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALY SIS CHECK SHEET...
Page 779 BR–93 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR–...
Page 780 ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details.
Page 781: Speed Sensor Circuit
BR–95 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. HINT: Using SST 09843–18020, connect the terminals Tc and E1, and remove the short pin. ABS Warning Light Diagnosis Code...
Page 782 BR–96 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. Turn the ignition switch to OFF. 2. Using SST, connect terminals Ts and E1 of DLC1. SST 09843–18020 3. Start the engine. 4. Check that the ABS warning light blinks HINT: If the ABS.
Page 783 DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.–6. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen.
Page 784 BR–98 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Page 785 BR–99 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCAT ION OF CONNECTORS Location of Connectors in Engine Compartment 1MZ–FE Engine:...
Page 786 BR–100 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 787 BR–101 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine:...
Page 788 BR–102 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 789 BR–103 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Instrument Panel...
Page 790 BR–104 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 791 BR–105 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 792 BR–106 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) J/B No. 1 J/B No. 3...
Page 793 BR–107 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Body...
Page 794 BR–108 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,12 ABS Control (Solenoid) Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No.
Page 795 BR–109 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 796 BR–110 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 2 and Check voltage between terminals 6 of ABS control relay connector. Disconnect the ABS control relay connector. Measure voltage between terminals A72 and A76 of ABS control relay harness side connec– tor.
Page 797 BR–111 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Continuity (Reference Terminals 1 and value 80W) Terminals Continuity 5 and Terminals Open 2 and 1. Apply battery positive voltage between termi– nals A7 1 and A6 3.
Page 798 BR–112 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 13,14 ABS Control (Motor) Relay Circuit CIRCUIT DESCRIPTION The ABS control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the control (motor) relay ON and operates the ABS pump motor. Diagnostic Trouble Code Detecting Condition Trouble area DTC No.
Page 799 BR–113 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 800 BR–114 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals 1 of ABS control relay and body ground. Disconnect the ABS control relay connector. Measure voltage between terminals A6 1 of ABS control relay harness side connector and body ground.
Page 801 BR–115 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) control relay. Check ABS Check continuity between each terminal of ABS control relay. Continuity (Reference Terminals 3 and value 62W) Open Terminals 1 and 1. Apply battery positive voltage between termi– nals A6 3 and A6 4.
Page 802 BR–116 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21, 22, 23, 24 ABS, Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. Trouble area Diagnostic Trouble Code Detecting Condition DTC No.
Page 803 BR–117 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 804 BR–118 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A5 4and A4 1, 3, 4, 6 of ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.2 Replace ABS actuator.
Page 805 BR–119 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31, 32, 33, 34, 35, 36 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system.
Page 806 BR–120 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Replace speed sensor. Check speed sensor. Check for open and short in harness and con– Repair or replace harness or connector. hector between each speed sensor and ECU. Replace speed sensor or rotor. Check sensor rotor and sensor installation.
Page 807 BR–121 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k Measure resistance between terminals 1 and 2 of speed sensor connector and body ground.
Page 808 BR–122 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor–rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section).
Page 809 BR–123 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. Trouble area Diagnostic Trouble Code Detecting Condition DTC No. Battery. Vehicle speed is 3 km/h (1.9 mph) or more and IC regulator.
Page 810 BR–124 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 811 BR–125 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check battery positive voltage. Voltage: 10–14V Check and repair the charging system, Check voltage between terminals IG1 and GND of ABS ECU connector. Remove ABS ECU with connectors still connected. 1.
Page 812 BR–126 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/6 No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and com- ponents connected to ECU–IG fuse (See attached wiring diagram).
Page 813 BR–127 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION Trouble area Diagnostic Trouble Code Detecting Condition DTC No. Pump motor is not operating normally during ABS pump motor. initial check. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control.
Page 814 BR–128 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Repair stop light circuit (See page BE– Check operation of stop light.
Page 815 BR–129 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU and body ground.
Page 816 BR–130 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code.
Page 817 BR–131 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Repair or replace ABS warning light Check ABS warning light. bulb or circuit. Replace ABS control relay. Check ABS control relay. Check for open in harness and connector between GAUGE fuse and J/B No.
Page 818 BR–132 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter Troubleshooting on page BE–1 Replace bulb or combination meter assembly. Check ABS control relay. Disconnect the connectors from control relay. Check continuity between each terminal of ABS control relay.
Page 819 BR–133 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–93. Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? Check for short in harness and connector between warning light and DLC1 and ECU (See IN–28 page...
Page 820 BR–134 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Tc and E1 of even after Tc and E1 are connected,...
Page 821 BR–135 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM 1 MZ–FE: 5S–FE:...
Page 822 BR–136 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.
Page 823 BR–137 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Ts and E1 of...
Page 824 BR–138 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective.
Page 825 BR–139 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines.
Page 826 BR–140 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMM Made Vehicle BOSCH ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 827 Diagnostic Trouble Code Check Problem Symptoms Chart BR–143 P. BR–14$ Diagnostic Trouble Code Chart BR–160xBR–184 Sensor Check for Fluid Leakage Circuit Check Inspection BR–160–BR–184 BR–185 Identification of Problem Repair Confirmation Test : Diagnostic steps permitting the use Step of the TOYOTA hand–held.
Page 828 BR–142 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALY SIS CHECK SHEET...
Page 829 BR–143 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR–...
Page 830 ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details.
Page 831 BR–145 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. ABS Warning Light Diagnosis Code Blinking Pattern Open or short circuit in ABS solenoid relay circuit Open or short circuit in ABS motor relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel...
Page 832 BR–146 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. 2. Turn the ignition switch to OFF. 3. Using SST, connect terminals Ts and El of DLC1. SST 09843–18020 4.
Page 833 DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1. x 7. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen.
Page 834 BR–148 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Page 835 BR–149 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCAT ION OF CONNECTORS Location of Connectors in Engine Compartment 1M2–FE Engine:...
Page 836 BR–150 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 837 BR–151 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine:...
Page 838 BR–152 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 839 BR–153 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in instrument Panel...
Page 840 BR–154 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 841 BR–155 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 842 BR–156 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) J/B No. 1...
Page 843 BR–157 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Body Sedan: Coupe:...
Page 844 BR–158 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Wagon:...
Page 845 BR–159 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) –MEMO–...
Page 846 BR–160 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,13 ABS Solenoid and Motor Relay Circuit CIRCUIT DESCRIPTION The solenoid relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. The motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay ON and operates the ABS pump motor.
Page 847 BR–161 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 848 BR–162 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between termi- 1 and 4 of ABS ECU nals connector. Disconnect the ABS ECU connector. Measure voltage between terminals A5 1 and A5 4 of ABS ECU harness side connector. Voltage: 10–14 V Check and repair harness or connector.
Page 849 BR–163 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21, 22, 23 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. Diagnostic Trouble Code Detecting Condition Trouble area DTC No.
Page 850 BR–164 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 851 BR–165 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Remove the ABS ECU cover and disconnect 6–pin connector. Check continuity between terminals 1 and 2, 3 and 4, 5 and6. Continuity HINT: Resistance of each solenoid coil is 1.1 Replace ABS actuator.
Page 852 BR–166 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31,32,33,34,35, 36, 38, 39 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations.
Page 853 BR–167 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Replace speed sensor. Check speed sensor. Check for open and short in harness and con– Repair or replace harness or connector. nector between each speed sensor and ECU. Replace speed sensor or rotor. Check sensor rotor and sensor installation.
Page 854 BR–168 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k Measure resistance between terminals 1 and 2 of speed sensor connector and body ground.
Page 855 BR–169 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section).
Page 856 BR–170 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 +BS Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU, and the actuators. Diagnostic Trouble Code Detecting Condition Trouble area DTC No. (1) Voltage of 5V or more, or 9.4V or less, is applied for at least 60 sec.
Page 857 BR–171 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 858 BR–172 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check battery positive voltage. Voltage: 10–14 V Check and repair the charging system. Check voltage between terminals +BS and GND of ABS ECU connector. Disconnect ABS ECU connector. 1. Turn ignition switch ON. 2.
Page 859 BR–173 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/B No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in. a1I the harness and com- ponents connected to ECU–IG fuse (See at- tached wiring diagram).
Page 860 BR–174 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION Diagnostic Trouble Code Detecting Condition DTC No. Trouble area Pump motor is not operating normally during ABS pump motor. initial check. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the solenoid relay and prohibits ABS control.
Page 861 BR–175 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Repair stop light circuit (See page BE– Check operation of stop light.
Page 862 BR–176 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU connector and body ground.
Page 863 BR–177 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code.
Page 864 BR–178 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Repair or replace ABS warning light Check ABS warning light. bulb or circuit. Check for–open in harness and connector–be– tween GAUGE fuse and ECU. ABS warning light remains on. Repair circuit indicated by the code Is diagnostic trouble code output? output.
Page 865 BR–179 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter–Troubleshooting on page BE–1 Replace bulb or combination meter assembly. Check for open in harness and connector between GAUGE fuse and ECU (See page IN–27). Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–143.
Page 866 BR–180 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Tc and El of even after Tc and E1 are connected,...
Page 867 BR–181 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM 1 M^–FE: 5S–FE:...
Page 868 BR–182 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E 1 are connected, the ECU may be defective.
Page 869 BR–183 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which can not be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Ts and E1 of...
Page 870 BR–184 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals ¿¿and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defec- tive.
Page 871 BR–185 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines.
Page 872 BR–186 BRAKE SYSTEM – BRAKE BOOSTER BRAKE BOOSTER BRAKE BOOSTER REMOVAL 1. REMOVE MASTER CYLINDER (See page BR–12) 2. PUSH DOWN CHARCOAL CANISTER Loosen the clamp screw and push the charcoal canis– ter down slightly.
Page 873 BR–187 BRAKE SYSTEM – BRAKE BOOSTER 3. DISCONNECT VACUUM HOSE FROM BRAKE BOO – STER 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND CLEVIS PIN 6. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS (a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket.
Page 874 BR–188 BRAKE SYSTEM – BRAKE BOOSTER 8. CHECK AND ADJUST BRAKE PEDAL (See page BR–8) Check and adjust the brake pedal, then tighten the clevis lock nut. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) 9. PERFORM OPERATIONAL CHECK (See page BR–9)
Page 875 BR–189 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE (Single–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts.
Page 876 BR–190 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt.
Page 877 BR–191 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) 1 MZ–FE engine: Install a pad wear indicator plate on the inside pad. (b) Apply disc brake grease to both sides of the inner anti –squeal shim.
Page 878 BR–192 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1.
Page 879 BR–193 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed sir.
Page 880 BR–194 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine 12.0 mm (0.472 In.) 1 MZ–FE engine 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini–...
Page 881 BR–195 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020in.), install the disc in that position.
Page 882 BR–196 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SET RING CALIPER INSTALLATION 1. INSTALL 2 BRAKE PADS Install the inside and outside pads. 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts.
Page 883 BR–197 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) FRONT BRAKE (2–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts.
Page 884 BR–198 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt.
Page 885 BR–199 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 7. INSTALL NEW PADS (a) Install the pad wear indicator plate on the pad. (b) Apply disc brake grease to both sides of the inner anti–squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) Install the inner pad with the pad wear indicator plates facing upward.
Page 886 BR–200 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads with anti–squeal shims (c) 4 pad support plates CALIPER DISASSEMBLY...
Page 887 BR–201 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1.
Page 888 BR–202 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub.
Page 889 BR–203 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket and a hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.
Page 890 BR–204 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 26 ft–lbf) 3.
Page 891 BR–205 BRAKE SYSTEM – REAR BRAKE(Drum Brake) REAR BRAKE (Drum Brake) COMPONENTS REAR DRUM BRAKE REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2.
Page 892 BR–206 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. REMOVE FRONT SHOE (a) Using SST, disconnect the return spring. SST 09703–30010 (b) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (c) Disconnect the anchor spring from the front shoe and remove the front shoe.
Page 893 BR–207 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 8. REMOVE WHEEL CYLINDER Remove the 2 bolts and the wheel cylinder. 9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder. 2 boots 2 pistons 2 piston cups Spring REAR DRUM BRAKE COMPONENTS INSPECTION AND REPAIR...
Page 894 BR–208 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. REAR DRUM BRAKE INSTALLATION HINT: Assemble the parts in the correct direction as shown.
Page 895 BR–209 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 3. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. APPLY HIGH TEMPERATURE GREASE TO BACK – ING PLATE AND ADJUSTER (a) Apply high temperature grease to the brake shoe contact surfaces.
Page 896 BR–210 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (d) Using SST, install the shoe hold–down spring, cups and pin. SST 09718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL FRONT SHOE (a) Install the anchor spring between the front and rear shoes.
Page 897 BR–211 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (c) Align the adjusting hole on the brake drum and largest hole on the axle carrier, install the brake drum. (d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard. 9.
Page 898 BR–212 BRAKE SYSTEM – REAR BRAKE(Disc Brake) REAR BRAKE (Disc Brake) COMPONENTS...
Page 899 BR–213 BRAKE SYSTEM – REAR BRAKE(Disc Brake) BRAKE PADS REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) 3.
Page 900 BR–214 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 4 anti–squeal shims (c) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–50) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7.
Page 901 BR–215 BRAKE SYSTEM – REAR BRAKE(Disc Brake) (c) Install the caliper and torque the installation bolt. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (d) Install the flexible hose bracket. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 9. INSTALL REAR WHEEL 14.
Page 902 BR–216 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. REMOVE 2 PADS Remove the inside and outside pads. 4. REMOVE MAIN PIN Loosen the. main pin installation bolt and remove the main pin. CALIPER DISASSEMBLY 1. REMOVE SLIDING BUSHING Pull out the sliding bushing. 2.
Page 903 BR–217 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. 5. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper.
Page 904 BR–218 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less.
Page 905 BR–219 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. INSTALL CYLINDER BOOT AND SET RING IN CYL– INDER 4. INSTALL DUST BOOTS (a) Place the caliper in vise. (b) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (c) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate.
Page 906 BR–220 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. INSTALL 2 PADS Install 2 pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 3.
Page 907 BR–221 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) REAR BRAKE (Parking Brake for Rear Disc Brake) COMPONENTS PARKING BRAKE DISASSEMBLY 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE ASSEMBLY (a) Remove the 2 mounting bolts and remove the disc brake assembly.
Page 908 BR–222 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 4. REMOVE SHOE RETURN SPRINGS Using needle–nose pliers, remove the shoe return springs. 5. REMOVE FRONT SHOE, ADJUSTER AND TENSION SPRING (a) Slide out the front shoe and remove the shoe adjuster. (b) Remove the shoe strut with the spring.
Page 909 BR–223 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 2. MEASURE BRAKE SHOE LINING THICKNESS Using a scale, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is excessively uneven wear, replace the brake shoe.
Page 910 BR–224 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 6. IF NECESSARY, REPLACE SHIM (a) Remove the parking brake lever, and install the cor– rect size shim. (b) Install the parking brake lever with a new C–washer. (c) Remeasure the clearance. PARKING BRAKE ASSEMBLY HINT: Assemble the parts in the correct direction as shown.
Page 911 BR–225 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 1. APPLY HIGH TEMPERATURE GREASE ON BACK – ING PLATE 2. APPLY HIGH TEMPERATURE GREASE TO ADJUSTER 3. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER (a) Install the shoe hold–down springs, cups and pins. (b) Using needle–nose pliers, connect the parking brake cable to the parking brake lever.
Page 912 BR–226 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) (d) Install the shoe strut with the spring. (e) Slide in the front shoe between the shoe hold–down spring cup and the backing plate. 6. INSTALL SHOE RETURN SPRINGS Using needle–nose pliers, install the shoe return spr–...
Page 913 BR–227 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 9. INSTALL DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mot nting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) 10. INSTALL REAR WHEEL 11. SETTLING PARKING BRAKE SHOES AND DISC (a) LEVER TYPE: With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbf) of force.
Page 914 BR–228 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE PARKING BRAKE PEDAL DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF PEDAL INSTALLATION INSTALL SHOCK ABSORBER (a) Loosen the union lock nut. (b) Install the shock absorber to the pin on the pedal bracket side, then extend the piston rod fully.
Page 915 BR–229 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE INTERMEDIATE LEVER DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF INTERMEDIATE LEVER INSTALLATION MEASURE CLEARANCE BETWEEN INTERMEDIATE LEVER SHAFT AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: 0.09–0.5 mm (0.004–0.02 in.) If the clearance is not within the specification, replace...
Page 916 BR–230 BRAKE SYSTEM – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) P VALVE INSPECTION 1. CONNECT FLUID PRESSURE GAUGE TO P VALVE 2. BLEED AIR FROM FLUID ’PRESSURE GAUGE 3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 5S–FE w/o ABS:...
Page 917 BR–231 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) LOAD SENSING PROPORTIONING VALVE (LSPV) COMPONENTS FLUID PRESSURE INSPECTION 1. SET REAR AXLE LOAD (a) Set the vehicle to its curb weight. (b) Measure the rear axle load and note the value. (c) Set the rear axle load.
Page 918 BR–232 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 3. RAISE FRONT BRAKE FLUID PRESSURE TO FOL– LOWING SPECIFICATION AND CHECK REAR BRAKE FLUID PRESSURE Rear brake fluid pressure: 5S–FE All, 1 MZ–FE w/ABS Front brake fluid pressure Rear brake fluid pressure kPa (kgf/cm , psi) kPa (kgf/cm...
Page 919 BR–233 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) (d) Torque the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) If it cannot be adjusted, replace the valve body. LSPV REMOVAL 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the valve body.
Page 920 BR–234 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 2. CONNECT BRAKE LINES Using SST, connect the brake lines. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 4.
Page 921 In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the ABS. An ABS actuator manufactured by BOSCH is used on the Camry produced by TMM (Toyota Motor Manufacturing U.S.A., Inc.).
Page 922 BR–236 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SYSTEM PARTS LOCATION...
Page 923 BR–237 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM TMC Made Vehicle/NIPPONDENSO ABS:...
Page 924 BR–238 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM TMM Made Vehicle/BOSCH ABS:...
Page 925 BR–239 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMC Made Vehicle/NIPPONDENSO ABS: Terminal Terminal Symbol Connection Connection Symbol Right front solenoid Left rear speed sensor Ground Right front speed sensor DLC2 DLC1, DLC2 Stop light switch ABS control (motor) relay monitor Sealed wiring harness Right rear speed sensor Left rear speed sensor...
Page 926 BR–240 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMM Made Vehicle/BOSCH ABS: Terminal Terminal Connection Symbol Connection Symbol A6S warning fight Battery Left rear speed sensor Ignition switch DLC1 Left rear speed sensor Ground Right front speed sensor Right rear speed sensor Left front speed sen- Stop light switch...
Page 927 BR–241 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMC Made Vehicle/NIPPONDENSO ABS: Symbols STD Voltage (V) Condition (Terminals No.) Always IG switch ON IG switch ON, ABS warning light OFF IG switch ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF...
Page 928 BR–242 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMM Made Vehicle/BOSCH ABS: Symbols STD Voltage (V) Condition (Terminals No.) Always IG switch ON IG switch ON, A6S warning light ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF Stop light switch OFF...
Page 929 BR–243 BRAKE SYSTEM – ANT!–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMC Made Vehicle NIPPONDENSO ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown.
Page 930 BR–244 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09023–00100 Torque: 15 N–m (155 kgf–cm. 11 ft–lbf) 2.
Page 931 BR–245 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10–14.5 V 2. DISCONNECT CONNECTORS (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3.
Page 932 BR–246 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (c) Place the ”SHEET A” (SST) on the actuator checker. SST 09990–00163 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle. (b) Turn the selector switch of the actuator checker to ”FRONT RH”...
Page 933 BR–247 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (l) Turn the selector switch to ”FRONT LH” position. (m) Repeat (c) to 6), checking the actuator operation sim– ilarly. (n) Similarly, inspect ”REAR RH” and ”REAR LH” position. HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position.
Page 934 BR–248 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMM Made Vehicle BOSCH ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown.
Page 935 BR–249 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 2.
Page 936 BR–250 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown.
Page 937 BR–251 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF DISASSEMBLY AND ASSEMBLY 1. REMOVE AND INSTALL COVER Using a T15 torx wrench, loosen and tighten the screw. Torque: 1.4 N–m(14 kgf–cm, 12 in.lbf) 2. DISCONNECT AND CONNECT 4–PIN AND 6–PIN CONNECTORS NOTICE: When installing, place the 4–pin connector’s cables into the cable guide.
Page 938 BR–252 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR COMPONENTS FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor.
Page 939 BR–253 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) 2. REMOVE SPEED SENSOR (a) Remove the 3 clamp bolts holding the sensor harness to the body and shock absorber_ (b) Remove the speed sensor from the steering knuckle. FRONT SPEED SENSOR INSTALLATION ¿¿”–07 1.
Page 940 BR–254 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR COMPONENTS REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor.
Page 941 BR–255 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. (c) Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber.
Page 942 BR–256 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (b) install the grommet securely. (c) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf)
Page 943 BR–257 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) –MEMO–...
Page 944 BR–258 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMC Made Vehicle NIPPONDENSO ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 945 BR–93 Diagnostic Trouble Code Chart Problem Symptoms Chart BR–95 BR–98 Sensor Check Circuit Inspection Check for Fluid Leakage BR–108XBR–138 BR–139 Identification of Problem Repair Confirmation Test Step Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box.
Page 946 BR–260 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALY SIS CHECK SHEET...
Page 947 BR–261 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR–...
Page 948 ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details.
Page 949 BR–263 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. HINT: Using SST 09843–18020, connect the terminals Tc and E1, and remove the short pin. ABS Warning Light Diagnosis Code...
Page 950 BR–264 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. Turn the ignition switch to OFF. 2. Using SST, connect terminals Ts and E1 of DLC1. SST 09843–18020 3. Start the engine. 4. Check that the ABS warning light blinks HINT: If the ABS.
Page 951 DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.–6. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen.
Page 952 BR–266 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Page 953 BR–267 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCAT ION OF CONNECTORS Location of Connectors in Engine Compartment 1MZ–FE Engine:...
Page 954 BR–268 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 955 BR–269 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine:...
Page 956 BR–270 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 957 BR–271 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Instrument Panel...
Page 958 BR–272 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 959 BR–273 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS)
Page 960 BR–274 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) J/B No. 1 J/B No. 3...
Page 961 BR–275 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Body...
Page 962 BR–276 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,12 ABS Control (Solenoid) Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No.
Page 963 BR–277 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 964 BR–278 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 2 and Check voltage between terminals 6 of ABS control relay connector. Disconnect the ABS control relay connector. Measure voltage between terminals A72 and A76 of ABS control relay harness side connec– tor.
Page 965 BR–279 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Continuity (Reference Terminals 1 and value 80W) Continuity Terminals 5 and Terminals Open 2 and 1. Apply battery positive voltage between termi– nals A7 1 and A6 3.
Page 966 BR–280 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 13,14 ABS Control (Motor) Relay Circuit CIRCUIT DESCRIPTION The ABS control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the control (motor) relay ON and operates the ABS pump motor. Diagnostic Trouble Code Detecting Condition Trouble area DTC No.
Page 967 BR–281 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 968 BR–282 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals 1 of ABS control relay and body ground. Disconnect the ABS control relay connector. Measure voltage between terminals A6 1 of ABS control relay harness side connector and body ground.
Page 969 BR–283 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) S control relay. Check AB Check continuity between each terminal of ABS control relay. Continuity (Reference Terminals 3 and value 62W) Open Terminals 1 and 1. Apply battery positive voltage between termi– nals A6 3 and A6 4.
Page 970 BR–284 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21 22 23 24 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. Trouble area Diagnostic Trouble Code Detecting Condition DTC No.
Page 971 BR–285 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 972 BR–286 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A5 4and A4 1, 3, 4, 6 of ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.2 Replace ABS actuator.
Page 973 BR–287 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31, 32, 33, 34, 35, 36 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system.
Page 974 BR–288 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Replace speed sensor. Check speed sensor. Check for open and short in harness and con– Repair or replace harness or connector. hector between each speed sensor and ECU. Replace speed sensor or rotor. Check sensor rotor and sensor installation.
Page 975 BR–289 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k Measure resistance between terminals 1 and 2 of speed sensor connector and body ground.
Page 976 BR–290 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor–rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section).
Page 977 BR–291 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. Trouble area Diagnostic Trouble Code Detecting Condition DTC No. Battery. Vehicle speed is 3 km/h (1.9 mph) or more and IC regulator.
Page 978 BR–292 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM...
Page 979 BR–293 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Remove ABS ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminals IG1 and G N D of ABS ECU connector. Voltage: 10–14 V Check continuity between terminals GND of ABS ECU connector and body ground.
Page 980 BR–294 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/6 No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and com- ponents connected to ECU–IG fuse (See attached wiring diagram).
Page 981 BR–295 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION Trouble area Diagnostic Trouble Code Detecting Condition DTC No. Pump motor is not operating normally during ABS pump motor. initial check. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control.
Page 982 BR–296 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Repair stop light circuit (See page BE– Check operation of stop light.
Page 983 BR–297 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU and body ground.
Page 984 BR–298 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code.
Page 985 BR–299 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Repair or replace ABS warning light Check ABS warning light. bulb or circuit. Replace ABS control relay. Check ABS control relay. Check for open in harness and connector between GAUGE fuse and J/B No.
Page 986 BR–300 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter Troubleshooting on page BE–1 Replace bulb or combination meter assembly. Check ABS control relay. Disconnect the connectors from control relay. Check continuity between each terminal of ABS control relay.
Page 987 BR–301 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–93. Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? Check for short in harness and connector between warning light and DLC1 and ECU (See IN–28 page...
Page 988 BR–302 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Tc and E1 of even after Tc and E1 are connected,...
Page 989 BR–303 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) WIRING DIAGRAM 1 MZ–FE: 5S–FE:...
Page 990 BR–304 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.
Page 991 BR–305 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART If ABS warning light does not blink Check voltage between terminals Ts and E1 of...
Page 992 BR–306 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective.
Page 993 BR–307 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines.
Page 994 BR–308 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMM Made Vehicle BOSCH ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem.
Page 995 Diagnostic Trouble Code Check Problem Symptoms Chart BR–143 P. BR–14$ Diagnostic Trouble Code Chart BR–160XBR–184 Sensor Check for Fluid Leakage Circuit Check Inspection BR–160–BR–184 BR–185 Identification of Problem Repair Confirmation Test : Diagnostic steps permitting the use Step of the TOYOTA hand–held.
Page 996 BR–310 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALY SIS CHECK SHEET...
Page 997 BR–311 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR–...
Page 998 ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details.
Page 999 BR–313 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. ABS Warning Light Diagnosis Code Blinking Pattern Open or short circuit in ABS solenoid relay circuit Open or short circuit in ABS motor relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel...
Page 1000 BR–314 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. 2. Turn the ignition switch to OFF. 3. Using SST, connect terminals Ts and El of DLC1. SST 09843–18020 4.