Toyota AVENSIS 1999 Supplement Manual

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This supplement has been prepared to provide information covering general service repairs for the chassis

and body of the TOYOTA AVENSIS/CORONA which underwent changes in August, 1999.

Applicable models: AT220, 221 series

For the service specifications and repair procedures of the above model other than those listed in this supple-

ment, refer to the following manuals.

Manual Name

AVENSIS/CORONA Chassis and Body Repair

Manual

4A–FE Engine Repair Manual

7A–FE Engine Repair Manual

4A–FE Engine Repair Manual Supplement

7A–FE Engine Repair Manual Supplement

4A–FE, 7A–FE Engine Repair Manual Supplement

3S–FE Engine Repair Manual

3S–FE Engine Repair Manual Supplement

1C, 2C, 2C–T Engine Repair Manual

All information in this manual is based on the latest product information at the time of publication. However,

specifications and procedures are subject to change without notice.

1999

TOYOTA MOTOR CORPORATION

duced or copied, in whole or in part, without the

written permission of Toyota Motor Corporation.

First Printing: Jun. 15, 1999 01–990615–00

FOREWORD

ST220 series

CT220 series

CDT220 series

AZT220 series

ZZT220, 221 series

Pub. No.

RM599E

RM296E

RM325E

RM397E

RM435E

RM611E

RM395E

RM495E

RM609E

RM025E

Manual Name

2C Engine Repair Manual Supplement

2C–T Engine Repair Manual Supplement

2C–T, 2C–TE Engine Repair Manual Supplement

1CD–FTV Engine Repair Manual

A241L, A241E Automatic Transaxle Repair Manual

A245E Automatic Transaxle Repair Manual

AVENSIS/CORONA Electrical Wiring Diagram

Supplement

AVENSIS/CORONA New Car Features

AVENSIS/CORONA New Car Features Supplement

TOYOTA MOTOR CORPORATION

Pub. No.

RM297E

RM494E

RM612E

RM697E

RM177E

RM350E

EWD330Y

EWD373F

NCF145E

NCF168E

Table of Contents

Chapters

Table of Contents

Summary of Contents for Toyota AVENSIS 1999

Page 1 FOREWORD This supplement has been prepared to provide information covering general service repairs for the chassis and body of the TOYOTA AVENSIS/CORONA which underwent changes in August, 1999. Applicable models: AT220, 221 series ST220 series CT220 series CDT220 series AZT220 series...
Page 2 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non–specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle.
Page 3 INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS E251 MANUAL TRANSAXLE SUSPENSION AND AXLE BRAKE STEERING SUPPLEMENTAL RESTRAINT SYSTEM BODY ELECTRICAL BODY AIR CONDITIONING ALPHABETICAL INDEX...
Page 4: Table Of Contents
INTRODUCTION HOW TO USE THIS MANUAL ... . . IN–1 GENERAL INFORMATION ....IN–1 IDENTIFICATION INFORMATION .
Page 6: How To Use This Manual
IN–1 – HOW TO USE THIS MANUAL INTRODUCTION HOW TO USE THIS MANUAL IN00U–34 GENERAL INFORMATION INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the section title and major heading are given at the top of every page.
Page 7 IN–2 – HOW TO USE THIS MANUAL INTRODUCTION The procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 8: Identification Information
IN–3 – IDENTIFICATION INFORMATION INTRODUCTION IDENTIFICATION INFORMATION IN06B–05 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped in the engine compartment. This number has also been stamped on the manufacturer ’s label. A: Vehicle Identification Number B: Manufacturer’s Label B02393 ENGINE SERIAL NUMBER...
Page 9: Repair Instructions
IN–4 – REPAIR INSTRUCTIONS INTRODUCTION REPAIR INSTRUCTIONS IN03Z–01 GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Installation and removal of battery terminal: FI1066 Before performing electrical work, disconnect the negative (–) terminal cable from the battery.
Page 10 IN–5 – REPAIR INSTRUCTIONS INTRODUCTION Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where speci- fied and follow the proper work procedure.
Page 11 IN–6 – REPAIR INSTRUCTIONS INTRODUCTION After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: Do not open the cover or case of the ECU unless...
Page 12: Vehicle Lift And Support Locations
IN–7 – REPAIR INSTRUCTIONS INTRODUCTION IN040–02 VEHICLE LIFT AND SUPPORT LOCATIONS Front JACK POSITION Front Front center member Rear Rear suspension member CAUTION : When jacking–up the rear and front, make sure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION SUPPORT POSITION Safety stand and swing arm type lift...
Page 13 IN–8 – REPAIR INSTRUCTIONS INTRODUCTION PLATE TYPE LIFT Attachment HINT : Left and right set position Place the vehicle over the center of the lift. Align the cushion gum ends of the plate Front and rear set position with the attachment lower ends (A, C). Align the attachment upper end (B) with the front jack supporting point ( ).
Page 14: For All Of Vehicles
IN–9 – FOR ALL OF VEHICLES INTRODUCTION FOR ALL OF VEHICLES IN0EA–01 PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER The AVENSIS/ CORONA is equipped with an SRS (Sup- plemental Restraint System), such as the driver airbag, front passenger airbag, side airbags, curtain shield airbag and seat belt pretensioners.
Page 15 IN–10 – FOR ALL OF VEHICLES INTRODUCTION Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad (See Pub. No. RM599E, page RS–15), front passenger airbag assembly (See Pub. No. RM599E, page RS–28), side airbag assemblies (See page RS–11), curtain shield airbag assemblies (See page RS–25) and seat belt pretensioners (See Pub.
Page 16 IN–11 – FOR ALL OF VEHICLES INTRODUCTION STEERING WHEEL PAD (with Airbag) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surface facing up- ward may lead to a serious accident if the airbag in- flates for some reason.
Page 17 IN–12 – FOR ALL OF VEHICLES INTRODUCTION FRONT PASSENGER AIRBAG ASSEMBLY Always store a removed or new front passenger air- bag assembly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag inflates.
Page 18 IN–13 – FOR ALL OF VEHICLES INTRODUCTION SIDE AIRBAG ASSEMBLY Always store a removed or new side airbag assem- bly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ment direction facing down could cause a serious accident if the airbag inflates.
Page 19 IN–14 – FOR ALL OF VEHICLES INTRODUCTION CURTAIN SHIELD AIRBAG ASSEMBLY Always store a removed or new curtain shield air- bag assembly in a clear plastic bag, and keep it in a safe place. NOTICE: Protection bag is not reuse. CAUTION: Never disassemble the curtain shield airbag assembly Never measure the resistance of the airbag squib.
Page 20 IN–15 – FOR ALL OF VEHICLES INTRODUCTION SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pre- tensioner. (This may cause the pretensioner oper- ates, which is very dangerous.) Oil or water should not be put on the front seat outer belt and the front seat outer belt should not be cleaned with detergents of any kind.
Page 21 IN–16 – FOR ALL OF VEHICLES INTRODUCTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. Use only unleaded gasoline.
Page 22 IN–17 – FOR ALL OF VEHICLES INTRODUCTION FOR VEHICLES EQUIPPED WITH POWER WINDOW CONTROL SYSTEM When the battery is disconnected or the power to the window regulator motor is cut, the power window con- trol system does not operate. It is necessary to initialize the system in the following procedures. Otherwise window cannot be operated normally.
Page 23: How To Troubleshoot Ecu Controlled Systems
IN–18 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN00Z–24 GENERAL INFORMATION A large number of ECU controlled systems are used in the AVENSIS/CORONA. In general, the ECU con- trolled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot.
Page 24: How To Proceed With Troubleshooting
IN–19 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS IN06D–07 HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in DI section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit.
Page 25 IN–20 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Page 26 IN–21 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the AVENSIS/ CORONA fulfills various functions. The first function is the Diagnos- tic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting.
Page 27 IN–22 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms.
Page 28 IN–23 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle.
Page 29 IN–24 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs.
Page 30 IN–25 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble- shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed.
Page 31 IN–26 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the problem is still occurring.
Page 32 IN–27 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Diagnostic Trouble Code No. and Detection Item Circuit Description The major role and operation, etc. of the circuit and its component parts are explained.
Page 33: Inspection Procedure
IN–28 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS D Indicates the position of the ignition switch during the check. Inspection Procedure Use the inspection procedure to determine LOCK if the circuit is normal or abnormal, and if it Ignition Switch ON Ignition Switch LOCK (OFF) is abnormal, use it to determine whether the START...
Page 34 IN–29 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS IN011–03 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages.
Page 35 IN–30 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals.
Page 36 IN–31 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section.
Page 37 IN–32 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connector ter- minal), an open circuit can be checked for by conducting a volt- age check. Sensor As shown in Fig.
Page 38 IN–33 – HOW TO TROUBLESHOOT ECU CONTROLLED INTRODUCTION SYSTEMS Disconnect connector ”B” and measure the resis- Fig. 7 tance between terminal 1 of connector ”A” and body ground, and terminal 1 of connector ”B2” and body ground. Between terminal 1 of connector ”A” and body Sensor ground →...
Page 39: Terms
IN–34 – TERMS INTRODUCTION TERMS IN044–07 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti–Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Active Height Control Suspension Automatic Locking Retractor Alternator Amplifier Antenna...
Page 40 IN–35 – TERMS INTRODUCTION Front–Engine Front–Wheel–Drive FIPG Formed In Place Gasket Fusible Link Front Front–Engine Rear–Wheel–Drive Front–Wheel–Drive Ground Hatchback High High Intensity Discharge (Head Lamp) Hard Top Heated Windshield System Idle Air Control Independent Front Suspension Ignition Intermittent Instrument Panel Independent Rear Suspension Junction Block Junction Connector...
Page 41 Standard Switch System Transaxle TACH Tachometer Top Dead Center TEMP. Temperature TEMS TOYOTA Electronic Modulated Suspension Toyota Free–Tronic Transmission TOYOTA Motor Corporation Traction Control System Underdrive VENT Ventilator Vehicle Identification Number Vehicle Skid Control Vehicle Stability Control Vacuum Switching Valve...
Page 42 IN–37 – TERMS INTRODUCTION Second Two Wheel Drive Vehicle (4x2) Four Wheel Drive Vehicle (4x4)
Page 43 PREPARATION MANUAL TRANSAXLE (E251) ... . . PP–1 SUSPENSION AND AXLE ....PP–6 BRAKE ....... . . PP–11 STEERING .
Page 45: Manual Transaxle (E251
PP–1 – MANUAL TRANSAXLE (E251) PREPARATION MANUAL TRANSAXLE (E251) PP27T–01 SST (Special Service Tools) Oil Seal & Bearing Replacer Differential case oil seal 09223–15020 Oil Seal Puller Output shaft front bearing outer 09308–00010 race Transfer Bearing Replacer Differential case tapered roller 09316–20011 bearing Transmission &...
Page 46 PP–2 – MANUAL TRANSAXLE (E251) PREPARATION Bearing Remover 09950–00020 Bearing Remover Attachment Output shaft front bearing 09950–00030 Puller A Set 5th driven gear 09950–30011 No.3 clutch hub Puller B Set Differential case tapered roller bearing 09950–40011 Replacer Set 09950–60010 Replacer 58 Input shaft bearing (09951–00580) Replacer Set No.2...
Page 47 09025–00010 Pin Punch . 09031–00030 Hexagon Wrench Set . 09040–00011 Torx Socket T50 . 09042–00040 Torx Socket T45 . 09042–00050 TOYOTA Electrical Tester. 09082–00040 Hose Plug Set . 09258–00030 Snap Ring No.1 Expander . 09905–00012 Snap Ring Pliers . 09905–00013...
Page 48 PP–4 – MANUAL TRANSAXLE (E251) PREPARATION PP0VE–02 EQUIPMENT Dial indicator with magnetic base Feeler gauge Magnetic finger Micrometer Plastigage Precision straight edge Torque wrench Vise...
Page 49 PP–5 – MANUAL TRANSAXLE (E251) PREPARATION PP0VF–02 LUBRICANT Item Capacity Classification API GL–4 or GL–5 Manual transaxle oil (w/ Differential oil) 3.9 liters (4.1 US qts, 3.4 Imp. qts) SAE 75W–90...
Page 50: Suspension And Axle
PP–6 – SUSPENSION AND AXLE PREPARATION SUSPENSION AND AXLE PP27U–01 SST (Special Service Tools) Wire Gauge Set 09240–00020 Transmission & Transfer Bearing 09316–60011 Replacer Replacer ”C” (09316–00041) Drive Shaft Remover Attachment 09520–01010 Differential Side Gear Shaft 09520–24010 Puller Shocker Set (09520–32040) Drive Shaft Boot Clamping Tool 09521–24010...
Page 51 PP–7 – SUSPENSION AND AXLE PREPARATION Bearing Remover 09950–00020 Replacer Set No.2 09950–60020 Replacer 72 (09951–00720) Handle Set 09950–70010 Handle 150 (09951–07150)
Page 52 PP–8 – SUSPENSION AND AXLE PREPARATION PP27V–01 RECOMMENDED TOOLS Snap Ring No.1 Expander . Front drive shaft 09905–00012...
Page 53 PP–9 – SUSPENSION AND AXLE PREPARATION PP11I–02 EQUIPMENT Torque wrench...
Page 54 PP–10 – SUSPENSION AND AXLE PREPARATION PP11J–02 LUBRICANT Item Capacity Application 1CD–FTV engine: Outboard joint grease Color=Black 85 – 105 g (3.00 – 3.70 oz.) Inboard joint grease Color=Yellow 120 – 130 g (4.23 – 4.59 oz.)
Page 55: Brake
PP–11 – BRAKE PREPARATION BRAKE PP27W–01 EQUIPMENT Torque wrench Micrometer Blade...
Page 56: Steering
PP–12 – STEERING PREPARATION STEERING PP27X–01 SST (Special Service Tools) Power Steering Pressure Gauge Power steering fluid 09640–10010 Gauge Assy (09641–01010) Attachment B (09641–01030) Attachment E (09641–01060) Replacer Set PS vane pump 09950–60010 (2C–T, 2C–TE and 1CD–FTV engines) Replacer 31 (09951–00310) Handle Set PS vane pump...
Page 57 PP–13 – STEERING PREPARATION PP27Y–01 RECOMMENDED TOOLS Torque Wrench (30 kgf–cm) PS vane pump 09025–00010 Belt Tension Gauge . 09216–00021 Belt Tension Gauge Cable . 09216–00030...
Page 58 PP–14 – STEERING PREPARATION PP27Z–01 EQUIPMENT Caliper gauge PS vane pump (2C–T, 2C–TE and 1CD–FTV engines) Vernier calipers PS vane pump (2C–T, 2C–TE and 1CD–FTV engines) Feeler gauge PS vane pump (2C–T, 2C–TE and 1CD–FTV engines) Micrometer PS vane pump (2C–T, 2C–TE and 1CD–FTV engines) Torque wrench...
Page 59 PP–15 – STEERING PREPARATION PP280–01 LUBRICANT Item Capacity Classification Power steering fluid Total 0.8 liters (0.8 US qts, 0.7 Imp. qts) ATF DEXRON® II or III...
Page 60: Supplemental Restraint System
PP–16 – SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM PP281–01 SST (Special Service Tools) SRS Airbag Deployment Tool 09082–00700 Airbag Deployment Wire Side airbag assembly 09082–00750 Sub–harness No.3 Curtain shield airbag assembly Diagnosis Check Wire 09843–18020...
Page 61 PP–17 – SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION PP282–01 RECOMMENDED TOOLS Torx Socket T40 . Airbag sensor assembly 09042–00020 Seatback assembly TOYOTA Electrical Tester Set. 09082–00050 TOYOTA Electrical Tester. 09082–00040...
Page 62 PP–18 – SUPPLEMENTAL RESTRAINT SYSTEM PREPARATION PP0MS–05 EQUIPMENT Torque wrench Tire Width: 185 mm (7.28 in.) Inner diam.: 360 mm (14.17 in.) Airbag disposal Tire with disc wheel Width: 185 mm (7.28 in.) Airbag disposal Inner diam.: 360 mm (14.17 in.) Vinyl bag Airbag disposal...
Page 63: Body Electrical
PP–19 – BODY ELECTRICAL PREPARATION BODY ELECTRICAL PP12J–02 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb (3.4 W) Fuel sender gauge, Dry cell battery Fuel sender gauge...
Page 64: Body
PP–20 – BODY PREPARATION BODY PP060–04 EQUIPMENT Clip remover Torque wrench Tape To avoid surface damage Adhesive tape To avoid surface damage Adhesive Cleaner Shop rag Knife Heat light Piano wire...
Page 65 PP–21 – BODY PREPARATION PP284–01 SSM (Special Service Materials) Three cement black or equivalent 08833–00030 Windshield Glass Adhesive Set 08850–00801 or equivalent...
Page 66: Air Conditioning
PP–22 – AIR CONDITIONING PREPARATION AIR CONDITIONING PP285–01 SST (Special Service Tools) Air Conditioner Service Tool Set 07110–58060 Refrigerant Drain Service Valve (07117–58060) T–Joint (07117–58070) Quick Disconnect Adapter High pressure side (07117–58080) Quick Disconnect Adapter Low pressure side (07117–58090) Refrigerant Charging Hose High pressure side (07117–88060) (Color: Red)
Page 67 PP–23 – AIR CONDITIONING PREPARATION PP286–01 RECOMMENDED TOOLS Belt Tension Gauge . 09216–00021 Belt Tension Gauge Cable . 09216–00030...
Page 68 PP–24 – AIR CONDITIONING PREPARATION PP095–04 EQUIPMENT Ohmmeter Torque wrench Hexagon wrench Expansion valve, Combustion type power heater...
Page 69 SERVICE SPECIFICATIONS STANDARD BOLT ......SS–1 MANUAL TRANSAXLE (E251) ... . . SS–4 SUSPENSION AND AXLE .
Page 71: Standard Bolt
SS–1 – STANDARD BOLT SERVICE SPECIFICATIONS STANDARD BOLT SS0ZS–01 HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt Class Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/ Washer w/ Washer B06431...
Page 72 SS–2 – STANDARD BOLT SERVICE SPECIFICATIONS SS0ZT–01 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Class Hexagon head bolt Hexagon flange bolt N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf 1.25 12.5 1.25 1.25 1,150 – – –...
Page 73 SS–3 – STANDARD BOLT SERVICE SPECIFICATIONS SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Present Standard Class Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/ Washer) No Mark (w/ Washer) No Mark 7N (5T) 10N (7T)
Page 74: Manual Transaxle (E251
SS–4 – MANUAL TRANSAXLE (E251) SERVICE SPECIFICATIONS MANUAL TRANSAXLE (E251) SS0G6–02 SERVICE DATA Input shaft 3rd & 4th gear journal diameter Min. 35.950 mm (1.4154 in.) 5th gear journal diameter Min. 27.950 mm (1.1004 in.) Runout Max. 0.05 mm (0.0020 in.) Output shaft 1st gear journal diameter Min.
Page 75 SS–5 – MANUAL TRANSAXLE (E251) SERVICE SPECIFICATIONS Input shaft snap ring thickness Mark No.3 clutch hub 1.75 mm (0.0689 in.) 1.80 mm (0.0709 in.) 1.85 mm (0.0729 in.) 1.90 mm (0.0748 in.) 1.95 mm (0.0768 in.) 2.00 mm (0.0787 in.) 2.05 mm (0.0807 in.) 2.10 mm (0.0827 in.) 2.15 mm (0.0847 in.)
Page 76 SS–6 – MANUAL TRANSAXLE (E251) SERVICE SPECIFICATIONS Output shaft bearing preload (at starting) New bearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) Reused bearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf) Output shaft rear bearing adjusting shim thickness Mark 1.30 mm (0.0512 in.)
Page 77 SS–7 – MANUAL TRANSAXLE (E251) SERVICE SPECIFICATIONS SS0G7–04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Transaxle upper side x Engine Bolt A Bolt B Transaxle lower side x Engine Bolt A Bolt B Bolt C 71 in.·lbf Bolt D Bolt E Diesel throttle body x Engine unit No.1 air tube assembly x Engine unit Diesel throttle body with No.2 air tube assembly x Engine unit...
Page 78 SS–8 – MANUAL TRANSAXLE (E251) SERVICE SPECIFICATIONS Transmission case x Transaxle case Transmission oil pipe x Transaxle case Reverse shift arm bracket assembly x Transaxle case Transmission oil pump assembly x Transaxle case Transaxle case receiver x Transaxle case 65 in.·lbf Clutch release fork support Control lever housing support bracket x Transaxle case Vehicle speed sensor...
Page 79: Suspension And Axle
SS–9 – SUSPENSION AND AXLE SERVICE SPECIFICATIONS SUSPENSION AND AXLE SS0IY–02 SERVICE DATA 852.15 ± 2.0 mm (33.55 ± 0.079 in.) Front drive shaft Drive shaft standard length (1CD–FTV engine) 548.15 ± 2.0 mm (21.58 ± 0.079 in.)
Page 80 SS–10 – SUSPENSION AND AXLE SERVICE SPECIFICATIONS SS0IZ–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drive shaft center bearing bracket set bolt Lower suspension arm x Lower ball joint 1,300 Tie rod and x steering knuckle Axle hub x Drive shaft 2,200 ABS speed sensor set bolt 71 in.·lbf...
Page 81: Brake
SS–11 – BRAKE SERVICE SPECIFICATIONS BRAKE SS14B–01 SERVICE DATA Vacuum Pump Blade Minimum height 16.20 mm (0.6378 in.) (1CD–FTV) Minimum width 5.95 mm (0.2343 in.) Minimum length 44.96 mm (1.7701 in.)
Page 82 SS–12 – BRAKE SERVICE SPECIFICATIONS SS0FT–04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Brake pedal x Brake pedal bracket 36.8 End cover x Casing 68 in.·lbf Check valve x End cover Union x Check valve Vacuum pump x Engine...
Page 83: Steering
SS–13 – STEERING SERVICE SPECIFICATIONS STEERING SS0IF–02 SERVICE DATA DRIVE BELT 4A–FE and 7A–FE engines: Drive belt deflection New belt 5 – 6 mm (0.20 – 0.24 in.) Drive belt deflection Used belt 6 – 8 mm (0.24 – 0.31 in.) *Drive belt tension New belt 441 –...
Page 84 SS–14 – STEERING SERVICE SPECIFICATIONS SS0IG–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf PS VANE PUMP (2C–T, 2C–TE and 1CD–FTV engines) Pressure port union x Front housing Suction port union set bolt Pulley cover x PS vane pump assembly PS vane pump assembly set bolt Union bolt x Pressure feed tube PS vane pump pulley set nut Idler pulley set nut...
Page 85: Supplemental Restraint System
SS–15 – SUPPLEMENTAL RESTRAINT SYSTEM SERVICE SPECIFICATIONS SUPPLEMENTAL RESTRAINT SYSTEM SS061–28 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Steering wheel x Steering main shaft Front passenger airbag assembly x Instrument panel reinforcement Seatback frame set bolt Front seat installation bolt Front seat belt lap outer ancher set bolt Curtain shield airbag (infrater) x Instrument panel reinforcement 87 in.·lbf...
Page 86: Body Electrical
SS–16 – BODY ELECTRICAL SERVICE SPECIFICATIONS BODY ELECTRICAL SS0JK–03 SERVICE DATA SPEEDOMETER (ON–VEHICLE) EUROPE MODELS : Standard indication (mph) Allowable range (mph) 20 – 24.5 40 – 46.5 60 – 68.5 80 – 90.5 100 – 112.5 Standard indication (km/h) Allowable range (km/h) 20 –...
Page 87 SS–17 – BODY ELECTRICAL SERVICE SPECIFICATIONS FUEL SENDER GAUGE Float position mm (in.) Resistance (Ω) F : Approx.19.76 (0.78) ±3 (0.12) Approx.4.0 ±1.0 E : Approx. 92.7 (3.65) ±3 (0.12) Approx.107.0 ±1.0...
Page 88: Body
SS–18 – BODY SERVICE SPECIFICATIONS BODY SS0K4–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT WIPER AND WASHER – – – Wiper arm x Wiper link INSTRUMENT PANEL – – – Curtain shield air bag x Body Steering wheel set nut Passenger airbag assembly x Reinforcement FRONT SEAT –...
Page 89: Air Conditioning
SS–19 – AIR CONDITIONING SERVICE SPECIFICATIONS AIR CONDITIONING SS038–05 SERVICE DATA 450 ± 50 g (15.87 ±1.76 oz.) Refrigerant volume Drive belt deflection (apply load of 9.8N) – 1CD–FTV New belt 11.0 – 13.0 mm (0.43 – 0.51 in.) Used belt 15.0 –18.0 mm (0.59 –...
Page 90 SS–20 – AIR CONDITIONING SERVICE SPECIFICATIONS SS050–04 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Compressor bracket Idle pulley lock nut Compressor x Discharge hose Compressor x Suction hose Pressure plate x Compressor 13.2...
Page 91 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM . . . DI–1 PRE–CHECK ......DI–1 DIAGNOSTIC TROUBLE CODE CHART .
Page 93: Supplemental Restraint System
DI–1 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI693–01 PRE–CHECK RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the SRS. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration on the following pages, insert paper which has the same thickness as the male terminal, between the terminal and short spring.
Page 94 DI–2 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Side Airbag Assembly (RH) (Squib) Pretensioner (RH) (Squib) Side and Curtain Shied Airbag Sensor (RH) Curtain Shied Airbag Assembly (RH) (Squib) Front Airbag Sensor (RH) Front Passenger Airbag Assembly (Squib) Spiral Cable Airbag Sensor Steering Wheel Assembly Pad (Squib)
Page 95 DI–3 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Airbag Sensor Assembly Connector Short Spring Short Spring Short Spring After Release Before Release Paper 8 21 Connector Connector 10 19 Connector Short Spring Short Spring Short Spring Before Release After Release Paper Paper H01356 H01233 AB0130...
Page 96: Diagnostic Trouble Code Chart
DI–4 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI694–01 DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). DTC No.
Page 97: Parts Location
DI–5 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI695–01 PARTS LOCATION Steering Wheel Pad (with Airbag) Curtain Shield Airbag Curtain Shield Airbag Assembly (RH) Assembly (LH) Front Airbag Sensor (RH) Combination Meter (Warning Light) Side Airbag Assembly (RH) Front Passenger Airbag Assembly Front Airbag Sensor (LH) Seat Belt...
Page 98: Terminals Of Ecu
DI–6 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI696–01 TERMINALS OF ECU H01357 Symbol Terminal Name – Electrical Connector Check Mechanism – Electrical Connector Check Mechanism C4 – 1 SFL– Squib (Side, LH) C4 – 2 SFL+ Squib (Side, LH) C4 – 5 Squib (Seat Belt Pretensioner, LH) C4 –...
Page 99 DI–7 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Symbol Terminal Name C5 – 20 SR– Front Airbag Sensor (RH) C5 – 26 SL– Front Airbag Sensor (LH) C5 – 27 Ground C5 – 28 Ground C6 – 1 PR– Squib (Seat Belt Pretensioner, RH) C6 –...
Page 100: Circuit Inspection
DI–8 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI697–01 CIRCUIT INSPECTION Short in Curtain Shield Airbag Squib (RH) Circuit (to Ground) CIRCUIT DESCRIPTION The curtain shield airbag squib (RH) circuit consists of the airbag sensor assembly and curtain shield airbag (RH). It causes the curtain shield airbag (RH) to activate when the curtain shield airbag assembly (RH) activation conditions are satisfied.
Page 101 DI–9 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS INSPECTION PROCEDURE Prepare for inspection. (See step 1 on page DI–285 of Pub. No. RM599E) Check curtain shield airbag squib (RH) circuit. CHECK: For the connector (on the airbag sensor assembly side) be- Curtain tween the curtain shield airbag assembly (RH) and airbag sen- Airbag Shield...
Page 102 DI–10 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. → ← Curtain Using a service wire, connect ICR+ and ICR– of the con- Shield Airbag nector (on the curtain shield airbag assembly side) be- Sensor Airbag tween the curtain shield airbag assembly (RH) and the...
Page 103 DI–11 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (RH). PREPARATION: Turn ignition switch to LOCK. Curtain Disconnect negative (–) terminal cable from the battery, → ← Airbag Shield Sensor and wait at least for 90 seconds. Airbag Assembly Connect the curtain shield airbag assembly (RH) connec- Squib (RH)
Page 104 DI–12 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI698–01 Short in Curtain Shield Airbag Squib (RH) Circuit (to B+) CIRCUIT DESCRIPTION The curtain shield airbag squib (RH) circuit consists of the airbag sensor assembly and curtain shield airbag assembly (RH). It causes the curtain shield airbag assembly (RH) to activate when the curtain shield airbag assembly (RH) activation conditions are satisfied.
Page 105 DI–13 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. → ← Using a service wire, connect ICR+ and ICR– of the con- Curtain Airbag Shield nector (on the curtain shield airbag assembly side) be- Sensor Airbag tween the curtain shield airbag assembly (RH) and airbag...
Page 106 DI–14 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (RH). PREPARATION: Turn ignition switch to LOCK. Curtain Disconnect negative (–) terminal cable from the battery, Airbag Shield and wait at least for 90 seconds. Sensor Airbag Assembly Connect the curtain shield airbag assembly (RH) connec- →...
Page 107 DI–15 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI699–01 Short in Curtain Shield Airbag Squib (RH) Circuit CIRCUIT DESCRIPTION The curtain shield airbag squib (RH) circuit consists of the airbag sensor assembly and curtain shield airbag assembly (RH). It causes the curtain shield airbag assembly (RH) to activate when the curtain shield airbag assembly (RH) activation conditions are satisfied.
Page 108 DI–16 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: → ← Connect the connector to the airbag sensor assembly. Curtain Using a service wire, connect ICR+ and ICR– of the con- Airbag Shield Sensor nector (on the curtain shield airbag assembly side) be- Airbag Assembly tween the curtain shield airbag assembly (RH) and airbag...
Page 109 DI–17 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (RH). PREPARATION: Turn ignition switch to LOCK. Curtain → ← Airbag Disconnect negative (–) terminal cable from the battery, Shield Sensor Airbag and wait at least for 90 seconds. Assembly Squib (RH) Connect the curtain shield airbag assembly (RH) connec-...
Page 110 DI–18 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI69A–01 Open in Curtain Shield Airbag Squib (RH) Circuit CIRCUIT DESCRIPTION The curtain shield airbag squib circuit (RH) consists of the airbag sensor assembly and curtain shield airbag assembly (RH). It causes the curtain shield airbag assembly (RH) to activate when the curtain shield airbag assembly (RH) activation conditions are satisfied.
Page 111 DI–19 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. Curtain Using a service wire, connect ICR+ and ICR– of the con- Airbag Shield nector (on the curtain shield airbag assembly side) be- Sensor Airbag Assembly...
Page 112 DI–20 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (RH). PREPARATION: Turn ignition switch to LOCK. Curtain Airbag Disconnect negative (–) terminal cable from the battery, Shield Sensor Airbag and wait at least for 90 seconds. Assembly → ← Squib (RH) Connect the curtain shield airbag assembly (RH) connec- tor.
Page 113 DI–21 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI69B–01 Short in Curtain Shield Airbag Squib (LH) Circuit (to Ground) CIRCUIT DESCRIPTION The curtain shield airbag squib (LH) circuit consists of the airbag sensor assembly and curtain shield airbag assembly (LH). It causes the curtain shield airbag assembly (LH) to activate when the curtain shield airbag assembly (LH) activation conditions are satisfied.
Page 114 DI–22 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS INSPECTION PROCEDURE Prepare for inspection. (See step 1 on page DI–285 of Pub. No. RM599E) Check curtain shield airbag squib (LH) circuit. CHECK: For the connector (on the airbag sensor assembly side) be- Curtain tween the curtain shield airbag assembly (LH) and airbag sen- Airbag Shield...
Page 115 DI–23 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. Using a service wire, connect ICR– and ICR+ of the con- Curtain Airbag Shield Sensor nector (on the curtain shield airbag assembly side) be- Airbag Assembly tween the curtain shield airbag assembly (LH) and airbag...
Page 116 DI–24 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (LH). PREPARATION: Turn ignition switch to LOCK. Curtain Airbag Disconnect negative (–) terminal cable from the battery, Shield Sensor Airbag and wait at least for 90 seconds. Assembly → ← Squib (LH) Connect the curtain shield airbag assembly (LH) connec- tor.
Page 117 DI–25 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI69C–01 Short in Curtain Shield Airbag Squib (LH) Circuit (to B+) CIRCUIT DESCRIPTION The curtain shield airbag squib (LH) circuit consists of the airbag sensor assembly and curtain shield airbag assembly (LH). It causes the curtain shield airbag assembly (LH) to activate when the curtain shield airbag assembly (LH) activation conditions are satisfied.
Page 118 DI–26 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. Curtain Using a service wire, connect ICL+ and ICL– of the con- Airbag Shield Sensor nector (on the curtain shield airbag assembly side) be- Airbag Assembly tween the curtain shield airbag assembly (LH) and airbag...
Page 119 DI–27 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (LH). PREPARATION: Turn ignition switch to LOCK. Curtain Airbag Disconnect negative (–) terminal cable from the battery, Shield Sensor and wait at least for 90 seconds. Airbag Assembly → ← Squib (LH) Connect the curtain shield airbag assembly (LH) connec- tor.
Page 120 DI–28 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI69D–01 Short in Curtain Shield Airbag Squib (LH) Circuit CIRCUIT DESCRIPTION The curtain shield airbag squib (LH) circuit consists of the airbag sensor assembly and curtain shield airbag assembly (LH). It causes the curtain shield airbag assembly (LH) to activate when the curtain shield airbag assembly (LH) activation conditions are satisfied.
Page 121 DI–29 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. Curtain Using a service wire, connect ICL+ and ICL– of the con- Airbag Shield Sensor nector (on the curtain shield airbag assembly side) be- Airbag Assembly Squib (LH)
Page 122 DI–30 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (LH). PREPARATION: Turn ignition switch to LOCK. Curtain Airbag Disconnect negative (–) terminal cable from the battery, Shield Sensor Airbag and wait at least for 90 seconds. Assembly → ← Squib (LH) Connect the curtain shield airbag assembly (LH) connec- tor.
Page 123 DI–31 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS DI69E–01 Open in Curtain Shield Airbag Squib (LH) Circuit CIRCUIT DESCRIPTION The curtain shield airbag squib circuit (LH) consists of the airbag sensor assembly and curtain shield airbag assembly (LH). It causes the curtain shield airbag assembly (LH) to activate when the curtain shield airbag assembly (LH) activation conditions are satisfied.
Page 124 DI–32 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check airbag sensor assembly. PREPARATION: Connect the connector to the airbag sensor assembly. Using a service wire, connect ICL+ and ICL– of the con- Curtain Airbag Shield Sensor nector (on the curtain shield airbag assembly side) be- Airbag Assembly tween the curtain shield airbag assembly (LH) and airbag...
Page 125 DI–33 – SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTICS Check curtain shield airbag squib (LH). PREPARATION: Turn ignition switch to LOCK. Airbag Curtain Disconnect negative (–) terminal cable from the battery, Sensor Shield and wait at least for 90 seconds. Assembly Airbag → ← Connect the curtain shield airbag assembly (LH) connec- Squib (LH) tor.
Page 126 MANUAL TRANSAXLE (E251) TROUBLESHOOTING ....MX–1 MANUAL TRANSAXLE UNIT ....MX–2 MANUAL TRANSAXLE ASSEMBLY .
Page 128 MX–1 – TROUBLESHOOTING MANUAL TRANSAXLE (E251) TROUBLESHOOTING MX01Z–04 PROBLEM SYMPTOMS TABLE 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. Symptom Suspect Area See page...
Page 129 MX–2 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) MANUAL TRANSAXLE UNIT MX096–02 COMPONENTS VSV Connector for EGR Air Cleaner Case Assembly Air Flow Meter with Air Hose Connector No.1 Air Tube Assembly 25 (255, 18) Clip Control Cable Turbo Pressure Sensor Connector Clip 15 (153, 11)
Page 130 MX–3 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) 64 (650, 47) Speed Sensor RH Drive Shaft Connector Back–Up Light Switch Connector LH Drive z Snap Ring 8.0 (82, 71in.·lbf) Shaft Ground Cable 20 (204, 15) 216 (2,200, 159) 29 (300, 22) 46 (470, 34) Lock Nut Cap 64 (650, 47)
Page 131 MX–4 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) MX097–02 REMOVAL REMOVE BATTERY AND TRAY REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE REMOVE LH AND RH ENGINE UNDER COVERS REMOVE NO.1 AIR TUBE ASSEMBLY Disconnect the No.2 vacuum hose from the E–VRV for EGR.
Page 132 MX–5 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) REMOVE STARTER Remove the 2 bolts and disconnect the radiator reservoir from the radiator. Disconnect the starter connector. Remove the nut, and disconnect the starter wire. Torque: 15 N·m (153 kgf·cm, 11 ft·lbf) Remove the 2 bolts and starter.
Page 133 MX–6 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque: Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf) Nut B: 87 N·m (890 kgf·cm, 64 ft·lbf) D06632 REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle side and remove the bolt and bracket.
Page 134 MX–7 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) Remove the 2 hole plugs and hole cover. Remove the 7 bolts and center member. Torque: Bolt A: 73 N·m (740 kgf·cm, 54 ft·lbf) Bolt B: 52 N·m (540 kgf·cm, 38 ft·lbf) JACK UP TRANSAXLE SLIGHTLY Using a transmission jack, support the transaxle.
Page 135 MX–8 – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE (E251) MX05P–02 INSTALLATION Installation is in the reverse order of removal. (See page MX–4) HINT: After installation, check and inspect items as follows. Front wheel alignment (See Pub. No. RM599E, page SA–4). Do the road test.
Page 136 MX–9 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) MANUAL TRANSAXLE ASSEMBLY MX098–01 COMPONENTS 17 (175, 13) Clutch Release Fork Assembly Control Lever Housing with Bearing Support Bracket Clutch Release Fork Support 47 (480, 35) 17 (175, 13) Vehicle Speed Sensor Boot Transaxle Case Receiver Clutch Release...
Page 137 MX–10 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Reverse Shift Arm Bracket Assembly Snap Ring Reverse Shift Fork No.1 Shift Fork 24 (240, 17) L Straight Screw Plug 25 (250, 18) Seat Spring Ball No.1 Shift Fork Shaft Snap Ring 17 (175, 13) No.2 Shift Fork Shaft 25 (250, 18)
Page 138 MX–11 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Input Shaft Assembly Output Shaft Assembly z Tapered Roller Bearing Outer Race Reverse Idler Gear Reverse Idler Gear Shaft Shim L Lock Bolt Thrust Washer 29 (300, 22) 42 (430, 31) Rear Bearing Retainer Snap Ring Spacer 5th Driven Gear...
Page 139 MX–12 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) MX099–01 DISASSEMBLY REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH WITH GASKET Torque: 40 N·m (410 kgf·cm, 30 ft·lbf) REMOVE BOLT AND VEHICLE SPEED SENSOR Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) REMOVE NO.2 SELECTING BELLCRANK WITH SE- LECTING BELLCRANK SUPPORT Remove the 2 bolts and No.2 selecting bellcrank with the se-...
Page 140 MX–13 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. 09950–30011 Q05849 MEASURE 5TH GEAR THRUST CLEARANCE AND RADIAL CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.10 – 0.57 mm (0.0039 – 0.0224 in.) Maximum clearance: 0.65 mm (0.0256 in.) Z01304...
Page 141 MX–14 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Torque: 42 N·m (430 kgf·cm, 31 ft·lbf) REMOVE SNAP RING Using a snap ring expander, remove the input shaft rear bearing snap ring. Using 2 screwdrivers and a hammer, remove the 2 snap rings.
Page 142 MX–15 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) REMOVE SHIM HINT: At the time of reassembly, please refer to the following item. Install the previously selected shim by adjusting output shaft preload. (See page MX–21) MT0669 REMOVE OUTPUT SHAFT REAR TAPER ROLLER BEARING OUTER RACE Using SST and a hammer, remove the output shaft rear taper roller bearing outer race.
Page 143 MX–16 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT Torque: 24 N·m (240 kgf·cm, 17 ft·lbf) REMOVE NO.1 SHIFT FORK SHAFT Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft. HINT: At the time of reassembly, please refer to the following item.
Page 144 MX–17 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Remove the 2 bolts and oil pipe. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) Remove the 2 bolts and the oil pump assembly. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring from the No.3 clutch hub.
Page 145 MX–18 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) MX05W–02 INSPECTION INSPECT NO.5 SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direction while push- ing it to the outer No.5 synchronizer ring. Check that the ring locks.
Page 146 MX–19 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Using SST and a press, remove the inner race. 09950–00020 Q05164 Using SST and a press, install a new input shaft front bearing inner race. 09316–60011 (09316–00021) Q00141 IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING OUTER RACE AND OUTPUT SHAFT FRONT COVER Using SST, pull out the output shaft front bearing outer...
Page 147 MX–20 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Using SST and a socket wrench, remove the output shaft front bearing. 09950–00020, 09950–00030 Socket Wrench Q00245 Using SST and a press, install a new output shaft front bearing. 09316–60011 (09316–00071) Z00199 IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench (6 mm), remove the screw plug.
Page 148 MX–21 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) MX05X–02 REASSEMBLY Reassembly is in the reverse order of disassembly. (See page MX–12) NOTICE: When working with FIPG material, you must observe the follow- ing items. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
Page 149 MX–22 – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE (E251) Using a torque wrench, measure the preload. Preload (at starting): New bearing 0.8 – 1.6 N·m (8 – 16 kgf·cm, 6.9 – 13.9 in.·lbf) Reused bearing 0.5 – 1.0 N·m (5 – 10 kgf·cm, 4.3 – 8.7 in.·lbf) If the preload is not within the specification, select an appropri- ate adjusting shim.
Page 150 MX–23 – INPUT SHAFT MANUAL TRANSAXLE (E251) INPUT SHAFT MX028–03 COMPONENTS Spacer Synchronizer Ring 4th Gear Snap Ring Needle Roller Bearing 3rd Gear Needle Roller Bearing Rear Bearing Spring Snap Ring z Input Shaft Front Bearing Inner Race Synchronizer Ring No.2 Hub Sleeve No.2 Clutch Hub Shifting Key...
Page 151 MX–24 – INPUT SHAFT MANUAL TRANSAXLE (E251) MX029–03 DISASSEMBLY MEASURE 3RD AND 4TH GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 3rd gear: 0.10 – 0.35 mm (0.0039 – 0.0138 in.) 3rd Gear 4th gear: 0.10 – 0.55 mm (0.0039 – 0.0217 in.) 4th Gear Maximum clearance: Q06369...
Page 152 MX–25 – INPUT SHAFT MANUAL TRANSAXLE (E251) REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRO- NIZER RING AND 3RD GEAR Using a press, remove the No.2 hub sleeve, 3rd gear and syn- chronizer rings. REMOVE NEEDLE ROLLER BEARING Q00115...
Page 153 MX–26 – INPUT SHAFT MANUAL TRANSAXLE (E251) MX02A–03 INSPECTION INSPECT 3RD GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.
Page 154 MX–27 – INPUT SHAFT MANUAL TRANSAXLE (E251) MEASURE NO.2 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Page 155 MX–28 – INPUT SHAFT MANUAL TRANSAXLE (E251) MX02B–03 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE Install the 3 springs and shifting keys to the clutch hub. Front Install the hub sleeve to the clutch hub.
Page 156 MX–29 – INPUT SHAFT MANUAL TRANSAXLE (E251) MEASURE 3RD GEAR THRUST CLEARANCE (See page MX–24) INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, 4TH GEAR AND REAR BALL BEARING Install the spacer. Apply MP grease to the needle roller bearings. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
Page 157 MX–30 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) OUTPUT SHAFT MX02C–03 COMPONENTS Needle Roller Bearing 3rd Driven Gear Spacer 4th Driven Gear Inner Race 1st Gear Bearing Inner Race 2nd Gear Spacer No.1 Hub Sleeve Output Shaft Rear Bearing Needle Roller Bearing Spring 1st Gear Synchronizer Ring...
Page 158 MX–31 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) MX02D–04 DISASSEMBLY MEASURE 1ST AND 2ND GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st Gear 1st gear: 0.10 – 0.35 mm (0.0039 – 0.0138 in.) 2nd gear: 0.10 – 0.45 mm (0.0039 – 0.0177 in.) 2nd Gear Maximum clearance: Q06370...
Page 159 MX–32 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST GEAR Using a press, remove the No.1 hub sleeve and 1st gear. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING Z00222 REMOVE 1ST GEAR BEARING INNER RACE Using SST and a press, remove the 1st gear bearing inner race.
Page 160 MX–33 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) MX02E–03 INSPECTION INSPECT 1ST GEAR SYNCHRONIZER RING Check for wear or damage. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone.
Page 161 MX–34 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) MEASURE NO.1 SHIFT FORK AND HUB SLEEVE CLEARANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Page 162 MX–35 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) MX02F–03 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. Front INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE Install the 3 springs and shifting keys to the clutch hub. Install the hub sleeve to the clutch hub.
Page 163 MX–36 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) INSTALL BALL AND INNER RACE TO OUTPUT SHAFT HINT: Align the groove of the inner race and ball. Q06314 INSTALL SPACER, NEEDLE ROLLER BEARING, SYN- CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR Install the spacer.
Page 164 MX–37 – OUTPUT SHAFT MANUAL TRANSAXLE (E251) INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install a new output shaft front bearing. 09316–60011 (09316–00071) Z00392...
Page 165 MX–38 – OIL PUMP MANUAL TRANSAXLE (E251) OIL PUMP MX02G–03 COMPONENTS O–Ring Gasket Oil Strainer Oil Pump Driven Rotor 10 (105, 8) Transmission Oil Pump Oil Pump Drive Rotor Case Oil Pump Drive Gear Relief Valve Ball Spring Spring Holder Oil Pump Cover 10 (105, 8) N·m (kgf·cm, ft·lbf) : Specified torque...
Page 166 MX–39 – OIL PUMP MANUAL TRANSAXLE (E251) MX02H–02 INSPECTION CHECK ROTOR BODY CLEARANCE Install the oil pump drive gear to the drive rotor. Using a feeler gauge, measure the body clearance be- tween the drive rotor and oil pump case. Standard clearance: 0.10 –...
Page 167 MX–40 – SHIFT AND SELECT LEVER SHAFT MANUAL TRANSAXLE (E251) SHIFT AND SELECT LEVER SHAFT MX02I–03 COMPONENTS Control Shaft Cover Dust Boot Oil Seal Shift Interlock Plate Transmission Oil Baffle Shift Interlock Plate No.1 Compression Spring Snap Ring No.1 Select Spring Seat Slotted Spring Pin No.2 Shift Inner Lever No.2 Compression Spring...
Page 168 MX–41 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) DIFFERENTIAL CASE MX060–02 COMPONENTS Differential Spider Differential Pinion z Oil Seal Differential Side Gear Side Gear Thrust Washer Pinion Thrust Washer z Tapered Roller Bearing and Outer Race Vehicle Speed Sensor Drive Gear 63 (640, 46) Differential Right Case Differential Left Case...
Page 169 MX–42 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) MX09A–01 DISASSEMBLY NOTICE: When working with FIPG material, you must observe the follow- ing items. 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.
Page 170 MX–43 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) Remove the 2 differential side gears, side gear thrust washers, 4 differential pinions and pinion thrust washers from the differential left case. Z00284 Transmission Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver, remove the oil seal.
Page 171 MX–44 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) Using SST and a hammer, drive in a new oil seal. 09223–15020, 09950–70010 (09951–07150) Coat the lip of oil seal with MP grease. Q06288 Transaxle Case Side: IF NECESSARY, REPLACE OIL SEAL AND TAPERED ROLLER BEARING OUTER RACE Using a screwdriver and hammer, drive out the oil seal from the transaxle case.
Page 172 MX–45 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) MX09B–01 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. ASSEMBLE DIFFERENTIAL CASE Install the thrust washer to the side gear. Install the 4 pinions and thrust washers to the spider. Install the side gear and spider with the 4 pinions to the differential left case.
Page 173 MX–46 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) Heat the ring gear to about 100°C (212°F) in boiling wa ter. Carefully take the ring gear out of the water. Clean the contact surface of the ring gear with cleaning solvent. Quickly install the ring gear on the differential case. HINT: Align the matchmarks on the differential left case and contact the ring gear.
Page 174 MX–47 – DIFFERENTIAL CASE MANUAL TRANSAXLE (E251) ADJUST DIFFERENTIAL CASE SIDE BEARING PRE- LOAD Install a new lock nut to the output shaft. Turn the output shaft right and left 2 or 3 times to allow the bearings to settle. Q00036 Using a torque wrench, measure the preload.
Page 175 MX–48 – SHIFT LEVER AND CONTROL CABLE MANUAL TRANSAXLE (E251) SHIFT LEVER AND CONTROL CABLE MX09C–01 COMPONENTS Air Flow Meter Connector Air Cleaner Case Assembly with Air Hose D06624 Console Box Assembly Shift Lever Knob Parking Brake Cover Front Ash Receptacle Shift Lever Assembly 12 (120, 9) Clip...
Page 176 SUSPENSION AND AXLE FRONT DRIVE SHAFT ....SA–1 REFER TO AVENSIS/CORONA REPAIR MANUAL FOR CHASSIS AND BODY (Pub. No. RM599E) NOTE: The above pages contain only the points which differ from the above listed manual.
Page 178 SA–1 – FRONT DRIVE SHAFT SUSPENSION AND AXLE FRONT DRIVE SHAFT SA109–02 COMPONENTS 1CD–FTV Engine RH Drive Shaft Center Bearing Bracket 64 (650, 47) z Snap Ring LH Drive Shaft z Cotter Pin 49 (500, 36) Tie Rod End 8.0 (82, 71 in.·lbf) ABS Speed Sensor 216 (2,200, 159) z Cotter Pin...
Page 179 SA–2 – FRONT DRIVE SHAFT SUSPENSION AND AXLE 1CD–FTV Engine Outboard Joint Shaft z Boot z Dynamic Damper z Boot Clamp z Dynamic Damper Clamp z Boot z Boot Clamp z Boot Clamp z Boot Clamp z Snap Ring z Snap Ring Tripod z Snap Ring Inboard Joint Shaft...
Page 180 SA–3 – FRONT DRIVE SHAFT SUSPENSION AND AXLE SA10A–02 REMOVAL NOTICE: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the ve- hicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the ve- hicle weight on the hub bearing, first support it with the SST.
Page 181 SA–4 – FRONT DRIVE SHAFT SUSPENSION AND AXLE LH drive shaft: Using SST, remove the drive shaft. 09520–01010, 09520–24010 (09520–32040) Using a screwdriver, remove the snap ring. F02725...
Page 182 SA–5 – FRONT DRIVE SHAFT SUSPENSION AND AXLE SA10B–02 DISASSEMBLY CHECK DRIVE SHAFT Check to see that there is no obvious play in the outboard joint. Check to see that the inboard joint slides smoothly in the thrust direction. Check to see that there is no obvious play in the radial direction of the inboard joint.
Page 183 SA–6 – FRONT DRIVE SHAFT SUSPENSION AND AXLE REMOVE DUST COVER LH drive shaft: Using SST and a press, remove the dust cover from the inboard joint shaft. 09950–00020 R09716 RH drive shaft: Using a press, remove the dust cover from the inboard joint shaft.
Page 184 SA–7 – FRONT DRIVE SHAFT SUSPENSION AND AXLE SA10C–02 REASSEMBLY RH drive shaft: ASSEMBLE INBOARD JOINT SHAFT Using a pin punch and hammer, install the straight pin into the bearing case. SA1453 Using SST and a press, install a new bearing into the bearing case.
Page 185 SA–8 – FRONT DRIVE SHAFT SUSPENSION AND AXLE RH drive shaft: 89.3 – 90.3 mm (3.52 – 3.56 in.) Using a steel plate and press, install a new dust cover until the distance from the tip of center drive shaft to the dust cover reaches the specification, as shown in the illustra- tion.
Page 186 SA–9 – FRONT DRIVE SHAFT SUSPENSION AND AXLE ASSEMBLE BOOT CLAMPS TO BOTH BOOTS RH Drive Shaft Make sure that the 2 boots are on the shaft groove. Make sure that the 2 boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: 852.15 ±...
Page 187 SA–10 – FRONT DRIVE SHAFT SUSPENSION AND AXLE SA02Z–03 INSTALLATION LH drive shaft: INSTALL DRIVE SHAFT TO TRANSAXLE Install a new snap ring to the inboard joint shaft. Coat the gear oil to the inboard joint shaft and differential case sliding surface. Set the snap ring with opening side facing downward.
Page 188 BRAKE BRAKE PEDAL ......BR–1 VACUUM PUMP (1CD–FTV) ....BR–2 REFER TO AVENSIS/CORONA REPAIR MANUAL FOR CHASSIS AND BODY (Pub.
Page 190 BR–1 – BRAKE PEDAL BRAKE BRAKE PEDAL BR11N–01 COMPONENTS RHD M/T Clevis Pin Stop Light Switch Connector Stop Light Switch Clip Brake Pedal Bracket z Bushing Return Spring 36.8 (375, 27) Collar Cushion Plate Pedal Pad z Bushing Pedal Pad Brake Pedal Brake Pedal LHD M/T...
Page 191 BR–2 – VACUUM PUMP (1CD–FTV) BRAKE VACUUM PUMP (1CD–FTV) BR11O–01 COMPONENTS Oil Hose z O–Ring Vacuum Hose Vacuum Pump Vacuum Hose z O–Ring 21 (214, 15) Check Valve 74 (750, 54) Union z Snap Ring z Gasket Coupling 14 (140, 10) z Gasket z Gasket Casing...
Page 192 BR–3 – VACUUM PUMP (1CD–FTV) BRAKE BR11P–01 REMOVAL Vacuum Hose DISCONNECT 2 VACUUM HOSES AND OIL HOSE FROM VACUUM PUMP REMOVE VACUUM PUMP Remove the 2 bolts and vacuum pump. Remove the 2 O–rings from the vacuum pump. Oil Hose F08963...
Page 193 BR–4 – VACUUM PUMP (1CD–FTV) BRAKE BR11Q–01 DISASSEMBLY PLACE VACUUM PUMP IN VISE Using soft jaws on the vice, place the vacuum pump in the vice. NOTICE: Do not tighten the vise too tightly. REMOVE VACUUM HOSE UNION Remove the union bolt, union and 2 gaskets. F08966 REMOVE CHECK VALVE Remove the check valve and gasket.
Page 194 BR–5 – VACUUM PUMP (1CD–FTV) BRAKE REMOVE COUPLING Using a screw driver, remove the snap ring. Remove the coupling. F08972...
Page 195 BR–6 – VACUUM PUMP (1CD–FTV) BRAKE BR11R–01 INSPECTION INSPECT BLADE Check the blades for wear or damage. Using a micrometer, measure the height, width and length of the blades. Minimum height: 16.20 mm (0.6378 in.) Minimum width: 5.95 mm (0.2343 in.) Minimum length: 44.96 mm (1.7701 in.) If necessary, replace the blade.
Page 196 BR–7 – VACUUM PUMP (1CD–FTV) BRAKE BR11S–01 REASSEMBLY INSTALL COUPLING Place the coupling to the rotor shaft. Install a new snap ring to the rotor shaft. F08980 INSTALL ROTOR INTO CASING Coat the rotor with engine oil, and install it to the rotor shaft. INSTALL 5 BLADES Coat the 5 blades with engine oil.
Page 197 BR–8 – VACUUM PUMP (1CD–FTV) BRAKE INSTALL CHECK VALVE Install the check valve with a new gasket. Torque: 74 N·m (750 kgf·cm, 54 ft·lbf) New Gasket F08984 INSTALL VACUUM HOSE UNION Install the vacuum hose union and 2 new gaskets with the union New Gasket bolt.
Page 198 BR–9 – VACUUM PUMP (1CD–FTV) BRAKE BR11T–01 INSTALLATION INSTALL VACUUM PUMP Coat 2 new O–rings with engine oil, and install them to the vacuum pump. Insert the vacuum pump, align the coupling with slit of the camshaft. Install the 2 bolts. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) New O–Ring Vacuum Hose...
Page 199 STEERING DRIVE BELT ......SR–1 POWER STEERING FLUID ....SR–3 POWER STEERING VANE PUMP (2C–T, 2C–TE, 1CD–FTV)
Page 201 SR–1 – DRIVE BELT STEERING DRIVE BELT SR0I6–02 INSPECTION INSPECT DRIVE BELT Visually check the belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the belt, it should be P06717 replaced.
Page 202 SR–2 – DRIVE BELT STEERING HINT: ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a run- ning engine for 5 minutes or more. After installing a belt, check that it fits properly in the WRONG CORRECT...
Page 203 SR–3 – POWER STEERING FLUID STEERING POWER STEERING FLUID 4A–FE and 7A–FE Engines SR0I8–02 INSPECTION CHECK FLUID LEVEL Keep the vehicle level. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. 2C–T, 2C–TE, 3S–FE and 1CD–FTV Engines Fluid: ATF DEXRON II or III HINT:...
Page 204 SR–4 – POWER STEERING FLUID STEERING CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube from the PS vane pump [See Pub. No. RM599E on page SR–21 (4A–FE and 7A–FE engines), SR–24 (3S–FE engine) and see page SR–8 (2C–T, 2C–TE and 1CD–FTV engines)]. Connect SST, as shown in the illustration below.
Page 205 SR–5 – POWER STEERING FLUID STEERING With the engine idling, close the valve of the SST and ob- serve the reading on the SST. reservoir Minimum fluid pressure: 4A–FE and 7A–FE engines 8,238 kPa (84 kgf/cm , 1,195 psi) PS Gear Closed 3S–FE engine 9,022 kPa (92 kgf/cm...
Page 206 SR–6 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) POWER STEERING VANE PUMP (2C–T, 2C–TE, 1CD–FTV) SR0WB–01 COMPONENTS Union Bolt 52 (525, 38) Pressure Feed Tube Pulley Cover 39 (400, 29) Woodruff Key z Gasket 39 (400, 29) 43 (440, 32) PS Vane Pump Assembly Return Hose...
Page 207 SR–7 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) Pressure Port Union 69 (700, 51) z Shorter Straight Pin z O–Ring Side Front Plate Flow Control Valve z Longer Straight Pin z Snap Ring z O–Ring Spring z O–Ring Vane Pump Shaft 13 (130, 9)
Page 208 SR–8 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) SR0WC–01 REMOVAL REMOVE DRIVE BELT Loosen the idler pulley set nut. Loosen the belt tension adjusting bolt, and remove the drive belt. F03730 REMOVE VANE PUMP PULLEY Using SST to stop the pulley rotating, remove the pulley set nut.
Page 209 SR–9 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) SR0WD–01 DISASSEMBLY NOTICE: When using a vise, do not overtighten it. MEASURE PS VANE PUMP ROTATING TORQUE Check that the pump rotates smoothly without abnormal noise. Temporarily install the vane pump pulley set nut. Using a torque wrench, check the pump rotating torque.
Page 210 SR–10 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) REMOVE LONGER STRAIGHT PIN Using pliers, remove the longer straight pin from the front hous- ing.
Page 211 SR–11 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) SR0WE–01 Vane Pump INSPECTION Bushing Shaft NOTICE: When using a vise, do not overtighten it. MEASURE OIL CLEARANCE BETWEEN VANE PUMP SHAFT AND BUSHING Using a micrometer and caliper gauge, measure the oil clear- Front ance.
Page 212 SR–12 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) HINT: There are 5 vane plate lengths with the following rotor and cam ring marks: Rotor and cam Vane plate part Vane plate length ring mark number mm (in.) 14.996 – 14.998 None 44345–12010 (0.59039 –...
Page 213 SR–13 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 36.0 mm (1.417 in.) If it is not within the specification, replace the spring. R08702 IF NECESSARY, REPLACE OIL SEAL Vinyl Tape Using a screwdriver with vinyl tape wound around its tip,...
Page 214 SR–14 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) SR0WF–01 REASSEMBLY NOTICE: When using a vise, do not overtighten it. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID (See page SR–6) INSTALL LONGER STRAIGHT PIN Using a plastic hammer, tap in a new longer straight pin to the front housing.
Page 215 SR–15 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) INSTALL VANE PLATES Install the 10 plates with the round end facing outward. Round End INSTALL SIDE REAR PLATE Coat a new O–ring with power steering fluid and install it to the side rear plate.
Page 216 SR–16 – POWER STEERING VANE PUMP (2C–T, 2C–TE, STEERING 1CD–FTV) SR0WG–01 INSTALLATION INSTALL PULLEY COVER Install the pulley cover to the PS vane pump with the bolt. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) INSTALL PS VANE PUMP ASSEMBLY Install the PS vane pump to the pulley bracket and engine with the 3 bolts.
Page 217 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG ......RS–1 SIDE AIRBAG ASSEMBLY ....RS–9 CURTAIN SHIELD AIRBAG ASSEMBLY .
Page 219: Srs Airbag
RS–1 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG RS0IJ–01 PRECAUTION NOTICE: The AVENSIS / CORONA is equipped with SRS, which comprises a driver airbag, front passen- ger airbag, side airbag and curtain shield airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly lead- ing to a serious accident.
Page 220 RS–2 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM RS0IK–01 OPERATION SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled. The inflater contains a squib, igniter charge and gas generant, etc., and in- flates the bag when instructed by the side airbag sensor assem- bly.
Page 221 RS–3 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM SRS CONNECTORS Side Airbag Assembly (RH) (Squib) Pretensioner (RH) Side and Curtain Shield Airbag Sensor (RH) Curtain Shield Airbag Assembly (RH) (Squib) Front Airbag Sensor (RH) Front Passenger Airbag Assembly (Squib) Spiral Cable Steering Wheel Airbag Sensor Pad (Squib)
Page 222 RS–4 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM Terminal Twin–Lock Mechanism Spacer Each connector has a two–piece component con- sisting of a housing and a spacer. This design en- Housing ables the terminal to be locked securely by two lock- ing devices (the retainer and the lance) to prevent terminals from coming out.
Page 223 RS–5 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM FHalf Connection FComplete Connection Terminal for Terminal for Diagnosis Diagnosis Disconnection Detection Pin H01315 HINT: The connectors shown in this illustration are connectors ”1”, ”2” and ”3” in step 10. Connector Twin–Lock Mechanism With this mechanism connectors (male and female connectors) are locked by 2 locking devices to in- crease the connection reliability.
Page 224 RS–6 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than the pre- determined level, the SRS is activated automatically. A safing sensor is designed to go on at a smaller decelera- tion rate than the airbag sensor.
Page 225 RS–7 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM CONNECTION OF SIDE AND CURTAIN SHIELD AIR- BAG SENSOR CONNECTOR Align the male connector (of the side of sensor) and fe- male connector in the same direction as shown in the il- lustration and fit in them without rubbing. As they are fitted in, the outer slides rearward.
Page 226 RS–8 – SRS AIRBAG SUPPLEMENTAL RESTRAINT SYSTEM DISCONNECTION OF SIDE AIRBAG AND CURTAIN SHIELD AIRBAG CONNECTOR Place a finger on the slider. Slide the slider to release lock. Disconnect the connector. Slider Slider Disconnection is completed H01584 CONNECTION OF SIDE AIRBAG AND CURTAIN SHIELD AIRBAG CONNECTOR Align a lock part of male connector and a slider of female connector in the same direction as shown in the illustra-...
Page 227: Side Airbag Assembly
RS–9 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY RS0IL–01 COMPONENTS Headrest Headrest Support Lumber Support Adjusting Knob Seatback Frame zHog Ring Seatback Pad Side Airbag Assembly Seatback Cover 25 (255, 18) 25 (255, 18) Front Seat Cushion Inner Shield 37 (375, 27) Seat Track Cover...
Page 228 RS–10 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IM–01 REMOVAL NOTICE: If the wiring connector of the SRS is disconnected and the ignition switch is at ON or ACC position, DTCs will be recorded. Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts.
Page 229 RS–11 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IN–01 INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. (See Pub. No. RM599E on page DI–152) Do a visual check which includes the following items with the side airbag assembly installed in the vehicle. Check that there are no cuts or the frayed on seams and seatback cover.
Page 230 RS–12 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IO–01 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the side airbag assembly always first deploy the airbag in ac- cordance with the procedure described below. If any abnormal- ity occurs with the airbag deployment, contact the SERVICE DEPT.
Page 231 RS–13 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG DEPLOYMENT WHEN SCRAPPING VE- HICLE HINT: Battery Have a battery ready as the power source to deploy the airbag. Check functioning of the SST. (See Pub. No. RM599E on page RS–17) 09082–00700 AB0158 Disconnect the side airbag connector.
Page 232 RS–14 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Dispose of the side airbag assembly. CAUTION: The side airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag.
Page 233 RS–15 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Using a service–purpose wire harness, tie down the side airbag assembly. Wire Harness Wire harness: Stripped wire harness section Diameter 1.25 mm or more (0.0019 in or more) HINT: To calculate the square of the stripped wire harness section : Square = 3.14 x (Diameter) divided by 4 Stripped Wire Harness Section...
Page 234 RS–16 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Always tie down the side airbag assembly with the airbag door facing inside. NOTICE: The tire will be marked by the airbag deployment, so use the redundant tire. Check functioning of the SST. 09082–00700, 09082–00750 Battery AB0158...
Page 235 RS–17 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. Check that no one is within 10 m (33 ft) area around the tire which the side airbag assembly is tied to.
Page 236 RS–18 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IP–01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side airbag assembly or seatback cover. Case Replacing part If the side airbag has been deployed. Side airbag assembly If the side airbag has been found to be faulty in troubleshooting. Side airbag assembly If the side airbag assembly has cut during checking items.
Page 237 RS–19 – SIDE AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IQ–01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replac- ing parts, replace them with new parts. INSTALL THESE PARTS TO SEATBACK FRAME Install the seatback pad. Install the hog rings and seatback cover. Hang the hook of the seatback cover.
Page 238: Curtain Shield Airbag Assembly
RS–20 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM CURTAIN SHIELD AIRBAG ASSEMBLY RS0IR–01 COMPONENTS Sedan Model Liftback Model Wagon Model Rear Seat Outer Belt Roof Side Inner Garnish 42 (430, 31) Roof Side Deck Side Trim Inner Garnish Roof Side Cover and Panel Deck Trim Inner Garnish...
Page 239 RS–21 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Instrument Panel 18 (184, 13) No.1 Register Cowl Side Panel Heater Control Assembly Combination Meter Center Cluster Finish Panel Cluster Finish Panel Front Ash Receptacle Lower Finish Panel Glove Compartment Door Steering Wheel Column Cover No.1 Under Cover...
Page 240 RS–22 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM 5 (51, 44 in.·lbf) Grommet Grommet 9.8 (100, 87 in.·lbf) RH Curtain Shield Airbag Assembly Grommet Curtain Shield Airbag Connector Curtain Shield Airbag Connector LH Curtain Shield Airbag Assembly 9.8 (100, 87 in.·lbf) : Specified torque N·m (kgf·cm, ft·lbf) H11619...
Page 241 RS–23 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IS–01 REMOVAL NOTICE: If the wiring connector of the SRS is disconnected and the ignition switch is at ON or ACC position, DTCs will be recorded. Never use the airbag parts from another vehicle. When replacing parts, replace them with new parts.
Page 242 RS–24 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM REMOVE CURTAIN SHIELD AIRBAG ASSEMBLY Remove the instrument panel assembly. (See page BO–16) Disconnect the curtain shield airbag connector. NOTICE: When handling the airbag connector, take care not to dam- age the airbag wire harness. In the order shown in the illustration, remove the bolts and grommets, then remove the curtain shield airbag assem- bly.
Page 243 RS–25 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IT–01 INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. (See Pub. No.RM599E on page DI–152) Do a visual check which includes the following items with the curtain shield airbag assembly installed in the vehicle. Check cuts, minute cracks or marked discoloration on the front pillar garnishes.
Page 244 RS–26 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IU–01 DISPOSAL HINT: When scrapping vehicles equipped with an SRS or disposing of the curtain shield airbag assembly, always first deploy the air- bag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT.
Page 245 RS–27 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Disconnect the curtain shield airbag connector. NOTICE: When handling the airbag connector, take care not to dam- age the airbag wire harness. Curtain Shield Airbag Connector H11623 Install the SST. Connect the 2 SST connector to the airbag connec- tor.
Page 246 RS–28 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Always wash your hands with water after completing the operation. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the curtain shield airbag assembly still installed. DEPLOYMENT WHEN DISPOSING OF CURTAIN SHIELD AIRBAG ASSEMBLY NOTICE: When disposing of the curtain shield airbag assem-...
Page 247 RS–29 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Position the inflater of curtain shield airbag inside the tire with the airbag explosion direction facing in- side. Tire size : Must exceed the following dimensions: Width 185 mm (7.28 in.) Inner diameter 360 mm (14.17 in.) CAUTION: Make sure the wire harness is tight.
Page 248 RS–30 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM Install the SST. Curtain Shield Airbag Assembly Connect the connector of 2 SST to the curtain shield air- bag connector. Battery 09082–00700, 09082–00750 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock.
Page 249 RS–31 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IV–01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side airbag assembly. Case Replacing part If the curtain shield airbag has been deployed. Curtain shield airbag assembly If the curtain shield airbag has been found to be faulty in troubleshooting. Curtain shield airbag assembly If the curtain shield airbag assembly has been found to be faulty during checking items.
Page 250 RS–32 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM RS0IW–01 INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. Make sure that the curtain shield airbag assembly is installed with the specified torque. If the curtain shield airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the curtain shield...
Page 251 RS–33 – CURTAIN SHIELD AIRBAG ASSEMBLY SUPPLEMENTAL RESTRAINT SYSTEM INSTALL FRONT PILLAR GARNISH Install the front pillar garnish. Install the pillar garnish cover with the bolt. NOTICE: Be sure to tighten the bolt. Pillar Garnish Fell the pillar garnish cover. Cover 2 Clips H11626...
Page 252: Side And Curtain Shield Airbag Sensor Assembly
RS–34 – SIDE AND CURTAIN SHIELD AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM ASSEMBLY SIDE AND CURTAIN SHIELD AIRBAG SENSOR ASSEMBLY RS0IX–01 COMPONENTS Side and Curtain Shield Airbag Sensor Assembly 21 (210, 15) Front Seat Outer Belt Retractor 5.0 (51, 44 in.·lbf) 42 (430, 31) Center Piller Garnish Rear Door Scuff Plate...
Page 253 RS–35 – SIDE AND CURTAIN SHIELD AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM ASSEMBLY RS0IY–01 REMOVAL NOTICE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) REMOVE FRONT AND REAR SCUFF PLATE REMOVE CENTER PILLAR LOWER GARNISH...
Page 254 RS–36 – SIDE AND CURTAIN SHIELD AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM ASSEMBLY RS0IZ–01 INSPECTION VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check. (See Pub. No. RM599E on page DI–152) VEHICLES INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check.
Page 255 RS–37 – SIDE AND CURTAIN SHIELD AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM ASSEMBLY RS0J0–01 REPLACEMENT REPLACEMENT REQUIREMENTS In the following cases, replace the side ans curtain shield airbag sensor assembly. If the side airbag assembly and curtain shield airbag assembly has been deployed in a collision. If the side and curtain shield airbag sensor assembly has been found to be faulty in troubleshoot- ing.
Page 256 RS–38 – SIDE AND CURTAIN SHIELD AIRBAG SENSOR SUPPLEMENTAL RESTRAINT SYSTEM ASSEMBLY RS0J1–01 INSTALLATION NOTICE: Never use SRS parts from another vehicle. When re- placing parts, replace them with new ones. Never reuse the side and curtain shield airbag sensor assembly involved in a collision when the airbag has deployed.
Page 257: Wire Harness And Connector
RS–39 – WIRE HARNESS AND CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR RS0J2–01 LOCATION Curtain Shield Airbag Assembly (LH) Combination Meter (Warning Light) Front Airbag Sensor (RH) Steering Wheel Pad Spiral Cable Front Passenger Airbag Assembly (with Airbag) Curtain Shield Airbag Assembly (RH) Front Airbag Sensor (LH) Side Airbag Assembly (RH)
Page 258 RS–40 – WIRE HARNESS AND CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM RS0J3–01 INSPECTION HINT: The SRS wire harness is integrated with the instrument panel wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color.
Page 259 RS–41 – WIRE HARNESS AND CONNECTOR SUPPLEMENTAL RESTRAINT SYSTEM RS0J4–01 REPLACEMENT In the following cases, replace the wire harness or connector. If any part of the SRS wire harness or any connector has been found to be faulty in troubleshoot- ing.
Page 260 BODY ELECTRICAL FOG LIGHT SYSTEM ....BE–1 COMBINATION METER ....BE–2 REFER TO AVENSIS/CORONA REPAIR MANUAL FOR CHASSIS AND BODY (Pub.
Page 262 BE–1 – FOG LIGHT SYSTEM BODY ELECTRICAL FOG LIGHT SYSTEM BE196–02 INSPECTION INSPECT FRONT/REAR FOG LIGHT SWITCH CONTI- NUITY Switch position Tester connection Specified condition – No continuity ON (FRONT) 11 – 16 Continuity ON (FRONT/REAR) 10 – 11 – 16 Continuity If continuity is not as specified, replace the switch.
Page 263 BE–2 – COMBINATION METER BODY ELECTRICAL COMBINATION METER BE197–02 LOCATION 1CD–FTV Engine Low Oil Pressuer Warning Switch Vehicle Speed Sensor I12456...
Page 264 BE–3 – COMBINATION METER BODY ELECTRICAL BE198–02 CIRCUIT Connector ”A” Connector ”B” I04817...
Page 265 BE–4 – COMBINATION METER BODY ELECTRICAL SPEEDOMETER TACHOMETER WATER TEMP. FUEL OIL LEVEL ODO / TRIP DISPLAY METER OUTSIDE TEMP. DISPLAY CLOCK RHEOSTAT VOLTAGE STABILIZER Brake Warning Fuel filter Warning Discharge Waring Economy Indicator Turbo / Glow Plug Indicator Glow Plug Indicator ABS Warning Low Oil Pressure Warning Check Engine Warning...
Page 266 BE–5 – COMBINATION METER BODY ELECTRICAL Wire Harness Side Ground (Power) Tacho Pick–UP Sensor EFI ECU (3S–FE, 2C–TE Engine) EGR (2C–T Engine) Vehicle Speed Sensor EFI ECU Water Temperature Sender Gauge (2C–T Engine) Ground (Engine) Ground Outside Temperature Sender Gauge Ground (Fuel) Fuel Sender Gauge Ground (Power)
Page 267 BE–6 – COMBINATION METER BODY ELECTRICAL BE199–02 INSPECTION INSPECT SPEEDOMETER ON–VEHICLE Using a speedometer tester, inspect the speedometer for allow- able indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indica- tion error.
Page 268 BE–7 – COMBINATION METER BODY ELECTRICAL Compare the tester and tachometer indications. DC 13.5 V 25 °C at (77°F) Standard indication Allowable range 630 – 770 1,000 900 – 1,100 2,000 1,850 – 2,150 3,000 2,800 – 3,200 4,000 3,800 – 4,200 5,000 4,800 –...
Page 269 BE–8 – COMBINATION METER BODY ELECTRICAL INSPECT LOW OIL PRESSURE SWITCH CONTINUITY Disconnect the connector from the switch. Check that continuity exists between terminal and ground with the engine stopped. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 24.5 kPa (0.25 kgf/cm , 3.55 psi).
Page 270 BODY CLIP ........BO–1 WINDSHIELD .
Page 272: Clip
BO–1 – CLIP BODY CLIP BO19D–01 REPLACEMENT 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 Pliers...
Page 273 BO–2 – CLIP BODY Shape (Example) Removal/Installation Removal Installation Removal Installation V00012...
Page 274: Windshield
BO–3 – WINDSHIELD BODY WINDSHIELD BO0IO–04 COMPONENTS Roof Headlining w/ Curtain shield air bag: Front Pillar Garnish Map Light Assembly Sun Visor Front Pillar Garnish z Stopper Opening Trim Holder Inner Rear View Mirror Sun Visor z Dam z Windshield Outside Moulding Wiper Arm Windshield...
Page 275 BO–4 – WINDSHIELD BODY BO2J0–01 REMOVAL REMOVE THESE PARS Remove the front wiper arms. Remove the weatherstrip. : Clip Remove the cowl louver. Remove the sun visors and holders. Remove the map light assembly. Remove the assist grip. Remove the upper part of front door opening trims. H03507 w/ Curtain Shield Airbag: Using a screwdriver, raise the pillar garnish cover.
Page 276 BO–5 – WINDSHIELD BODY REMOVE WINDSHIELD GLASS Push piano wire through between the body and glass from the interior. Tie both wire ends to a wooden block or similar object. HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched.
Page 277 BO–6 – WINDSHIELD BODY BO2J1–01 INSTALLATION CLEAN AND SHAPE CONTACT SURFACE OF BODY Using a knife, cut away any rough areas on the body. Adhesive HINT: Leave as much of the adhesive on the body as possible. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner.
Page 278 BO–7 – WINDSHIELD BODY POSITION GLASS Place the glass in the correct position. Check that all contacting parts of the glass rim are perfect- ly even. Place reference marks between the glass and body. Remove the glass. BO2820 CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface which is black–col- ored area around the entire glass rim.
Page 279 BO–8 – WINDSHIELD BODY APPLY ADHESIVE Cut off the tip of the cartridge nozzle. Part No. 08850–00801 or equivalent HINT: After cutting off the tip, use all adhesive within the time de- scribed in the table below. Temperature Tackfree time a –...
Page 280 BO–9 – WINDSHIELD BODY Use a scraper to remove any excessive or protruding adhesive. Hold the windshield glass in place securely with protec- tive tape or equivalent until the adhesive hardenes. NOTICE: Take care not to drive the vehicle during the time described in the table below.
Page 281 BO–10 – WINDSHIELD BODY Install the upper part of roof headlining. Install the assist grip. Install the map light assembly. Install the sun visors and holders. Install the cowl louver. Install the weatherstrip. Install the front wiper arms. Torque: 20 N·m (205 kgf·cm, 15 ft·lbf)
Page 282: Sliding Roof
BO–11 – SLIDING ROOF BODY SLIDING ROOF BO199–02 REMOVAL REMOVE ROOF HEADLINING (See page BO–23 , BO–28 or BO–33) REMOVE SLIDING ROOF GLASS Using a torx wrench, remove the 4 screws. Pull the glass upward to remove it. H03711 REMOVE DRIVE GEAR Disconnect the connector.
Page 283 BO–12 – SLIDING ROOF BODY BO2J2–01 INSTALLATION INSTALL SLIDING ROOF HOUSING Install the housing with the 2bolts and 5nuts. Install the 4 brackets with the 8 bolts. Connect the 4 drain hoses to the housing. H03643 INSTALL DRIVE GEAR Install the drive motor with 2 screws. Connect the connector.
Page 284: Instrument Panel
BO–13 – INSTRUMENT PANEL BODY INSTRUMENT PANEL BO19J–02 COMPONENTS w/ Curtain shield air bag: Curtain Shield Airbag Reinforcement Front Pillar Garnish Front Pillar Garnish No.1 Brace Instrument Panel Front Door Opening Trim 18 (185, 13) No.1 Register Heater Control Assembly Combination Meter Cluster Finish Panel Front Ash Receptacle...
Page 285 BO–14 – INSTRUMENT PANEL BODY No.2 Side Defroster Duct Defroster Nozzle No.1 Side Defroster Duct No.3 Heater to Register Duct No.4 Heater to Register Duct Front Passenger Airbag Assembly No.1 Pin No.1 Pin No.2 Side Defroster No.1 Heater to Nozzle Register Duct No.2 Register Center Bracket...
Page 286 BO–15 – INSTRUMENT PANEL BODY HINT: Screw shapes and size are indicated in the table below. The codes (A – H) correspond to those indicated on the previous page. mm (in.) Shape Size Shape Size Shape Size ø = 8 ø...
Page 287 BO–16 – INSTRUMENT PANEL BODY BO2J3–01 REMOVAL REMOVE THESE PARTS: Remove the front door opening trims. Remove the front pillar garnishes. w/ Curtain Shield Airbag: Remove the 2 bolts. Pack the airbag with protection cover. Using a screwdriver, raise the pillar garnish cover. Remove the bolt, pillar garnish cover and front pillar garnish.
Page 288 BO–17 – INSTRUMENT PANEL BODY : 4 Clips REMOVE NO.1 REGISTER Using a screwdriver, remove the No.1 register. HINT: Tape the screwdriver tip before use. H03661 REMOVE NO.1 UNDER COVER : 3 Clips Using a screwdriver, remove the No.1 under cover. HINT: Tape the screwdriver tip before use.
Page 289 BO–18 – INSTRUMENT PANEL BODY REMOVE INSTRUMENT PANEL Remove the 2 bolts and front passenger airbag assembly. Remove the 6 screws and 3 nuts. REMOVE THESE PARTS: Remove the No.1 brace. Remove the reinforcement. H03666...
Page 290 BO–19 – INSTRUMENT PANEL BODY BO2J4–01 INSTALLATION INSTALL THESE PARTS: Install the reinforcement. Install the No.1 brace. INSTALL INSTRUMENT PANEL Install the 6 screws and 3 nuts. Install the passenger airbag assembly with the 2 bolts. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) INSTALL HEATER CONTROL ASSEMBLY (See Pub.
Page 291 BO–20 – INSTRUMENT PANEL BODY INSTALL NO.1 UNDER COVER : 3 Clips Install the No.1 under cover. H03662 INSTALL NO.1 REGISTER : 3 Clips Install the No.1 register. INSTALL COMBINATION METER H03661 INSTALL CLUSTER FINISH PANEL : 3 Clips Install the cluster finish panel, then connect the connec- tor.
Page 292 BO–21 – INSTRUMENT PANEL BODY w/ Curtain Shield Airbag: Remove the protection cover. Install the 2 bolts. Torque: 5.0 N·m (51 kgf·cm, 44 in.·lbf) Install the pillar garnish cover with the bolt. NOTICE: Be sure to tighten the bolt. Fell the pillar garnish cover. Install the front pillar garnishes.
Page 293: Roof Headlining (Sedan
BO–22 – ROOF HEADLINING (Sedan) BODY ROOF HEADLINING (Sedan) BO19O–02 COMPONENTS w/ Curtain shield air bag: Front Pillar Garnish Assist Grip Cushion w/ Sliding Roof: Assist Grip Cushion Assist Grip Assist Grip Roof Headlining Map Light Sliding Roof Sun Visor Opening Trim Map Light Room Light...
Page 294 BO–23 – ROOF HEADLINING (Sedan) BODY BO2J5–01 REMOVAL REMOVE THESE PARTS: Remove the front door opening trims. w/ Curtain Shield Airbag: Using a screwdriver,raise the pillar garnish cover. Remove the bolt, pillar garnish cover and front pillar garnish. H11626 Remove the 2 bolts. Pack the air bag with protection cover.
Page 295 BO–24 – ROOF HEADLINING (Sedan) BODY REMOVE ROOF SIDE INNER GARNISH : 4 Clips Remove the roof side inner garnish. REMOVE THESE PARTS: Remove the assist grips. Remove the sun visors and holders. Remove the room light. Remove the map light. w/ Sliding Roof: Remove the sliding roof opening trim.
Page 296 BO–25 – ROOF HEADLINING (Sedan) BODY BO2J6–01 INSTALLATION w/ curtain shield airbag: INSINSTALL CURTAIN SHIELD AIRBAG In order shown in the illustration, install the deployment section of the curtain shield airbag with the bolts and grommet. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) INSTALL ASSIST GRIP CUSHION INSTALL ROOF HEAD LINING Install the roof headlining with the 3 clips.
Page 297 BO–26 – ROOF HEADLINING (Sedan) BODY w/ Curtain Shield Airbag: Remove the protection cover. Install the 2 bolts. Torque: 5 N·m (51 kgf·cm, 44 in.·lbf) Install the front pillar garnish. Install the pillar garnish cover and bolt. NOTICE: Be sure to tighten the bolt. Fell the pillar garnish cover.
Page 298: Roof Headlining (Liftback
BO–27 – ROOF HEADLINING (Liftback) BODY ROOF HEADLINING (Liftback) BO19R–02 COMPONENTS Assist Grip Roof Headlining w/ Sliding Roof: Assist Grip Roof Headlining Map Light Sun Visor Room Light Sliding Roof Opening Trim Holder w/ Curtain shield air bag: Front Pillar Garnish Center Pillar Roof Side Inner Garnish Upper Garnish...
Page 299 BO–28 – ROOF HEADLINING (Liftback) BODY BO2J7–01 REMOVAL REMOVE THESE PARTS: Remove the front door opening trims. w/ Curtain Shield Airbag: Using a screwdriver,raise the pillar garnish cover. Remove the bolt, pillar garnish cover and front pillar garnish. H11626 Remove the 2 bolts. Pack the air bag with protection cover.
Page 300 BO–29 – ROOF HEADLINING (Liftback) BODY REMOVE ROOF SIDE INNER GARNISH : 5 Clips Remove the garnish. REMOVE THESE PARTS: Remove the assist grips. Remove the sun visors and holders. Remove the room light. Remove the map light. w/ Sliding Roof: Remove the sliding roof opening trim.
Page 301 BO–30 – ROOF HEADLINING (Liftback) BODY BO2J8–01 INSTALLATION w/ Curtain Shield Airbag: INSTALL CURTAIN SHIELD AIRBAG In order shown in the illustration, install the deployment section of the curtain shield airbag with the bolts and grommet. Torque: 9.8 N·m (100 kgf·cm, 7 ft·lbf) INSTALL ASSIST GRIP CUSHION INSTALL ROOF HEAD LINING Install the 3 clips and roof headlining.
Page 302 BO–31 – ROOF HEADLINING (Liftback) BODY w/ Curtain Shield Airbag: Remove the protection cover. Install the 2 bolts. Torque: 5 N·m (51 kgf·cm, 44 in.·lbf) Install the front pillar garnish. Install the pillar garnish cover and bolt. NOTICE: Be sure to tighten the bolt. Fell the pillar garnish cover.
Page 303: Roof Headlining (Wagon
BO–32 – ROOF HEADLINING (Wagon) BODY ROOF HEADLINING (Wagon) BO19U–02 COMPONENTS Rear Room Partition Net Hook Roof Headlining Assist Grip w/ Sliding Roof: Roof Headlining Assist Grip Map Light Sun Visor No.2 Room Light Room Light Rear Door Opening Trim Sliding Roof Opening Trim Holder Roof Side Inner Garnish...
Page 304 BO–33 – ROOF HEADLINING (Wagon) BODY BO2J9–01 REMOVAL REMOVE THESE PARTS: Remove the front door opening trims. w/ Curtain Shield Airbag: Using a screwdriver,raise the pillar garnish cover. Remove the bolt, pillar garnish cover and front pillar garnish. H11626 Remove the 2 bolts. Pack the air bag with protection cover.
Page 305 BO–34 – ROOF HEADLINING (Wagon) BODY REMOVE REAR SIDE SEATBACK Remove the bolt and rear side seatback. H03625 REMOVE DECK SIDE TRIM COVER : 2 Clips Using a screwdriver, remove the deck side trim cover. HINT: Tape the screwdriver tip before use. H03626 REMOVE DECK TRIM SIDE BOARD : 3 Clips...
Page 306 BO–35 – ROOF HEADLINING (Wagon) BODY Put the removed air bag in the clear plastic bag and put it on the instrument panel. H11614...
Page 307 BO–36 – ROOF HEADLINING (Wagon) BODY BO2JA–01 INSTALLATION w/ Curtain Shield Airbag: INSTALL CURTAIN SHIELD AIRBAG In order shown in the illustration, install the deployment section of the curtain shield airbag with the bolts and grommet. Torque: 9.8 N·m (100 kgf·cm, 7 ift·lbf) INSTALL ROOF HEAD LINING Install the 5 clips and roof headlining.
Page 308 BO–37 – ROOF HEADLINING (Wagon) BODY INSTALL REAR SIDE SEATBACK Install rear side seatback with the bolt. Torque: 21 N·m (214 kgf·cm, 15 ft·lbf) INSTALL REAR ROOM PARTITION NET HOOK Install the hook with the screw. H03625 INSTALL REAR FLOOR FINISH PLATE : Clip Install the rear floor finish plate.
Page 309 AIR CONDITIONING DRIVE BELT (1CD–FTV) ....AC–1 MANIFOLD GAUGE SET (1CD–FTV) ..AC–4 REFRIGERANT LINE ..... AC–6 COMBUSTION TYPE POWER HEATER .
Page 311: Drive Belt (1Cd-Ftv
AC–1 – DRIVE BELT (1CD–FTV) AIR CONDITIONING DRIVE BELT (1CD–FTV) AC2A4–01 ON–VEHICLE INSPECTION INSPECT DRIVE BELT INSTALLATION CONDITION Check that the drive belt fits properily in the ribbed grooves. Correct Wrong CH0086 INSPECT DRIVE BELT DEFLECTION PS Pump Using a belt tension gauge, apply load of 98 N (10 kgf, 22 lbf) and measure drive belt deflection.
Page 312 AC–2 – DRIVE BELT (1CD–FTV) AIR CONDITIONING AC2A5–01 REMOVAL REMOVE DRIVE BELT Drive Belt Loosen the idle pulley lock nut. Adjusting Bolt Loosen the drive belt tension by adjusting bolt and re- move the drive belt. Idle Pulley Lock Nut I02286...
Page 313 AC–3 – DRIVE BELT (1CD–FTV) AIR CONDITIONING AC2A6–01 INSTALLATION Drive Belt INSTALL DRIVE BELT Tighten the idle pulley lock nut temporarily. Adjusting Bolt Torque: 2.5 N·m (25 kgf·cm, 22 in.·lbf) Install the drive belt. Using a adjusting bolt, adjust drive belt tension. Drive belt tension: Idle Pulley Lock Nut New belt: 520 –...
Page 314: Manifold Gauge Set (1Cd-Ftv
AC–4 – MANIFOLD GAUGE SET (1CD–FTV) AIR CONDITIONING MANIFOLD GAUGE SET (1CD–FTV) AC2A7–02 SET ON CONNECT CHARGE HOSE TO MANIFOLD GAUGE Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand.
Page 315 AC–5 – MANIFOLD GAUGE SET (1CD–FTV) AIR CONDITIONING AC2A8–01 SET OFF CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to un- lock the adapter and remove it from the service valve.
Page 316: Refrigerant Line
AC–6 – REFRIGERANT LINE AIR CONDITIONING REFRIGERANT LINE AC1A5–02 ON–VEHICLE INSPECTION (1CD–FTV Engine Models) INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant.
Page 317 AC–7 – REFRIGERANT LINE AIR CONDITIONING AC1A6–03 COMPONENTS 1CD–FTV Engine Models Piping Clamp LHD: Liquid Tube Suction Hose 4A–FE and 7A–FE 10 (100, 7) Engine Models: 10 (100, 7) 32 (330, 24) 10 (100, 7) Discharge Hose Compressor Condenser 10 (100, 7) 10 (100, 7) RHD: Liquid Tube...
Page 318 AC–8 – REFRIGERANT LINE AIR CONDITIONING AC1A7–01 REPLACEMENT DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torque.
Page 319: Combustion Type Power Heater
AC–9 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING COMBUSTION TYPE POWER HEATER AC29V–02 ON–VEHICLE INSPECTION NOTICE: If the glow plug breaks, the ECU detects the breakage and stops the automatic operation, so the burner heater does not activate. (For other failures, similarly activated.) The cause of failures (such as voltage malfunction, overheating malfunction, short–circuit or breakage of functional componects, etc.) and how to remedy are shown by connecting the DTC tester and reading the DTC.
Page 320 AC–10 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING DESCRIPTION OF DISPLAY AND BUTTONS AF: Current Value Malfunction (Blinking at current failure) Diag: DTC (Example: 064 Flame sensor break) Mamory Clear button: Deletion of faulty memory (Press both buttons together for longer than 2 sec.) >...
Page 321 AC–11 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING ON–VEHICLE INSPECTION If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. DTC No. Description of fault Comment / Remedy No malfunction –...
Page 322 AC–12 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING DTC No. Description of fault Comment / Remedy Flame sensor break Check connecting leads. Resistance value between 7 and 14 at connector B > 3,040 Ω (If break) Flame sensor short–circuit Check connecting leads. Resistance value between 7 and 14 at connector B >...
Page 323 AC–13 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC29W–02 COMPONENTS Heater Hose (IN) Heater Hose (OUT) Fuel Line Intake Pipe Heater Connector I12467...
Page 324 AC–14 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING Cover Blower Cable Harness Cover Jacket Glow Plug Flame Sensor Overheat Sensor Plate Water Temperature Sensor z O–Ring Control Unit and Cover Electric Motor Complete z Gasket Combustion Chamber with Flame Tube Heat Excharger and Jacket z Gasket...
Page 325 AC–15 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC29X–01 REMOVAL REMOVE RH UNDER COVER DRAIN ENGINE COOLANT DISCONNECT HEATER HOSES Disconnect the inlet heater hose. Disconnect the outlet heater hose. I12474 DISCONNECT FUEL LINE Disconnect the fuel line from the fuel pump. DISCONNECT FUEL PUMP CONNECTOR DISCONNECT COMBUSTION TYPE POWER HEATER CONNECTOR...
Page 326 AC–16 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC29Y–01 DISASSEMBLY REMOVE JACKET COVER Remove the 4 screws and jacket cover. I12445 REMOVE BLOWER COVER Remove the 4 screws and blower cover. I12446 Control Unit REMOVE CONTROL UNIT AND COVER Remove the 2 screws. Remove the 2 hexagon screws.
Page 327 AC–17 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING REMOVE COMBUSTION CHAMBER WITH FLAME TUBE Remove the combustion chamber and gasket. I12451 REMOVE HEAT EXCHAMBER I12741...
Page 328 AC–18 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC29Z–01 INSPECTION Water Temperature Sensor INSPECT WATER TEMPERATURE SENSOR Measure the resistance between the terminals 6, 13. Using an ohmmeter, measure the resistance between the ter- Ohmmeter minals. Resistance: Refer to the graph If the resistance is not as speaified, replace the water tempera- ture sensor.
Page 329 AC–19 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING INSPECT FLAME SENSOR Measur the resistance between the terminal 7, 14. Ohmmeter 2.75 2.25 1.75 1.25 0.75 –50 450 500 550 I12754 I12497 I12481...
Page 330 AC–20 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC2A0–01 REASSEMBLY INSTALL HEAT EXCHAMBER Align slot on heat exchanger (arrow) with lug in jacket. I12452 INSTALL COMBUSTION CHAMBER WITH FLAME TUBE Install a new gasket and the combustion chamber. INSTALL ELECTRIC MOTOR Install a new gasket.
Page 331 AC–21 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING INSTALL JACKET COVER Install the jacket cover with the 4 screws. I12445...
Page 332 AC–22 – COMBUSTION TYPE POWER HEATER AIR CONDITIONING AC2A1–01 INSTALLATION INSTALL COMBUSTION TYPE POWER HEATER Install the combustion type power heater with the 2 bolts. I12476 CONNECT COMBUSTION TYPE POWER HEATER CONNECTOR CONNECT FUEL PUMP CONNECTOR CONNECT FUEL LINE Connect the fuel line to the fuel pump. I12475 CONNECT HEATER HOSES Connect the inlet heater hose.
Page 333: Electrical Type Power Heater
AC–23 – ELECTRICAL TYPE POWER HEATER AIR CONDITIONING ELECTRICAL TYPE POWER HEATER AC29T–01 COMPONENTS Glow Plug Engine Block Heater Bracket I12440...
Page 334 AC–24 – ELECTRICAL TYPE POWER HEATER AIR CONDITIONING AC29U–01 INSPECTION DRAIN ENGINE COOLANT REMOVE AIR CLEANER ASSEMBLY REMOVE GLOW PLUGS Remove the glow plug cap. Remove the 3 bolts. Remove the glow plug plate. Remove the glow plug stay. Remove the 3 glow plugs. I12479 INSPECT GLOW PLUGS Ohmmeter...
Page 335: Compressor And Magnetic Clutch (1Cd-Ftv
AC–25 – COMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV) AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV) AC2A9–01 ON–VEHICLE INSPECTION MAKE THESE VISUAL CHECKS: Leakage of grease from the clutch bearing Signs of oil on the pressure plate or rotor INSPECT MAGNETIC CLUTCH BEARING FOR NOISE Start the engine.
Page 336 AC–26 – COMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV) AIR CONDITIONING AC2AA–01 COMPONENTS Suction Hose Spacer 10 (100,7) Discharge Hose Drive Belt z O–Ring 25 (250, 18) N·m (kgf·cm, ft·lbf) : Specified torque Engine Under Cover RH z Non–reusable part I12486 Stator Pressure Plate 13.2 (135, 9) Compressor...
Page 337 AC–27 – COMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV) AIR CONDITIONING AC2AB–01 REMOVAL RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES WITH A/C ON STOP ENGINE DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REMOVE ENGINE UNDER COVER RH REMOVE DRIVE BELT (See page AC–2)
Page 338 AC–28 – COMPRESSOR AND MAGNETIC CLUTCH (1CD–FTV) AIR CONDITIONING AC2AC–01 INSTALLATION INSTALL COMPRESSOR Install the compressor with the 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the connector. CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with the 2 bolts. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) CAUTION: Hoses should be connected immediately after the caps...
Page 339: Relay (1Cd-Ftv
AC–29 – RELAY (1CD–FTV) AIR CONDITIONING RELAY (1CD–FTV) AC2AD–01 INSPECTION ELECTRICAL TYPE POWER HEATER Remove magnetic clutch relay (marking: HTR sub1, sub2, sub3) from engine room relay block. I12488 Inspect magnetic clutch relay (marking: HTR sub1, sub2, sub3) continuity. Condition Tester connection Specified condition Constant...
Page 340: Condenser Fan (1Cd-Ftv
AC–30 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING CONDENSER FAN (1CD–FTV) AC2AE–01 ON–VEHICLE INSPECTION INSPECT CONDENSER FAN OPERATION Inspect the fan operation, as shown in the chart below. Test conditions: Ignition switch ON Blower speed control dial at ”HI” position Temperature control dial at ”COOL” position Set on manifold gauge set A/C switch ON Condition...
Page 341 AC–31 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING AC2AF–01 COMPONENTS Condenser Fan Fan Shroud Fan Motor I12470...
Page 342 AC–32 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING AC2AG–01 REMOVAL DRAIN ENGINE COOLANT REMOVE RESERVOIR TANK Disconnect the upper hose. Disconnect the lower hose. Remove the 2 bolts and reservoir tank. REMOVE CONDENSER FAN Disconnect the connector. Remove the 3 bolts and condenser fan. I12494...
Page 343 AC–33 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING AC2AH–01 DISASSEMBLY REMOVE FAN Remove the nut and fan. Remove the fan motor. Disconnect the 3 wire harness clamps. Remove the 3 screws and fan motor. I12490...
Page 344 AC–34 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING AC2AI–01 REASSEMBLY INSTALL FAN Install the fan motor. Install the fan with the 3 screws. Connect the wire harness clamps. Install the fan with the nut. I12490...
Page 345 AC–35 – CONDENSER FAN (1CD–FTV) AIR CONDITIONING AC2AJ–01 INSTALLATION INSTALL CONDENSER FAN Install the fan with the 3 bolts. Connect the fan connector. INSTALL RESERVOIR TANK Install the reservoir tank with the 2 bolts. Install the lower hose. Install the upper hose. FILL ENGINE COOLANT I12494...
Page 346: Water Temperature Switch (1Cd-Ftv
AC–36 – WATER TEMPERATURE SWITCH (1CD–FTV) AIR CONDITIONING WATER TEMPERATURE SWITCH (1CD–FTV) AC2AK–01 INSPECTION REMOVE ENGINE UNDER COVER O–Ring DRAIN ENGINE COOLANT REMOVE WATER TEMPERATURE SWITCH Connector Disconnect the connector. Switch Remove the water temperature switch and O–ring. B08053 INSPECT WATER TEMPERATURE SWITCH OPERA- TION Using an ohmmeter, check that the no continuity exists between terminals when the coolant temperature is...
Page 347 ID–1 ALPHABETICAL INDEX...
Page 348 ID–2 ALPHABETICAL INDEX (A – S) Page HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ..... . IN–18 HOW TO USE THE DIAGNOSTIC CHART AND Page INSPECTION PROCEDURE ABBREVIATIONS USED IN THIS MANUAL...
Page 349 ID–3 ALPHABETICAL INDEX (S – W) Page SUPPLEMENTAL RESTRAINT SYSTEM (SERVICE SPECIFICATIONS) ....SS–15 SUSPENSION AND AXLE (PREPARATION) ..PP–6 SUSPENSION AND AXLE (SERVICE SPECIFICATIONS)

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Toyota AVENSIS 1999 Supplement Manual

Introduction

Preparation

Service Specifications

Diagnostics

Supplemental Restraint System

Table of Contents

Air Conditioning

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