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Toyota AVENSIS 2000 Supplement Manual

Toyota AVENSIS 2000 Supplement Manual

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Supplement manual (349 pages)

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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 July, 2000.

Applicable models: ZZT220, 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.

S

AVENSIS/CORONA Chassis and Body Repair Manual

S

AVENSIS/CORONA Chassis and Body Repair Manual Supplement (Aug., 1999)

S

1ZZ–FE, 3ZZ–FE Engine Repair Manual

S

1AZ–FSE Engine Repair Manual

S

3S–FE Engine Repair Manual

S

3S–FE Engine Repair Manual Supplement (Jan., 1996)

S

3S–FE Engine Repair Manual Supplement (Oct., 1997)

S

1CD–FTV Engine Repair Manual

S

A245E Automatic Transaxle Repair Manual

S

U240E Automatic Transaxle Repair Manual

S

AVENSIS/CORONA Electrical Wiring Diagram

S

AVENSIS/CORONA Electrical Wiring Diagram Supplement (May, 1999)

S

AVENSIS/CORONA Electrical Wiring Diagram Supplement (Jul., 2000)

S

AVENSIS/CORONA New Car Features

S

AVENSIS/CORONA New Car Features Supplement

S

TOYOTA Model New Car Features Supplement

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

specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

2000

All rights reserved. This book may not be repro-

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

written permission of Toyota Motor Corporation.

First Printing: May 17, 2000 01–000517–00

FOREWORD

AZT220 series

ST220 series

CDT220 series

Manual Name

TOYOTA MOTOR CORPORATION

Pub. No.

RM599E

RM698E

RM782E

RM783E

RM395E

RM495E

RM609E

RM697E

RM757E

RM740U

EWD330Y

EWD373F

EWD418F

NCF145E

NCF168E

NCF195E

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Table of Contents

Troubleshooting

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Summary of Contents for Toyota AVENSIS 2000

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 July, 2000. Applicable models: ZZT220, 221 series AZT220 series ST220 series CDT220 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.
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 CLUTCH C50, C250 MANUAL TRANSAXLE E351 MANUAL TRANSAXLE S54, S55 MANUAL TRANSAXLE A246E AUTOMATIC TRANSAXLE U240E AUTOMATIC TRANSAXLE SUSPENSION AND AXLE BRAKE STEERING 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 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL IN00U–65 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 INTRODUCTION – HOW TO USE THIS MANUAL The procedures are presented in a step–by–step format: The illustration shows what to do and where to do it. The task heading tells what to do. The detailed text tells how to perform the task and gives other information such as specifications and warnings.
Page 8: Identification Information
IN–3 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION IN06B–11 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 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as...
Page 9: Repair Instructions
IN–4 INTRODUCTION – REPAIR INSTRUCTIONS REPAIR INSTRUCTIONS IN03Z–03 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 INTRODUCTION – REPAIR INSTRUCTIONS 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 INTRODUCTION – REPAIR INSTRUCTIONS 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 INTRODUCTION – REPAIR INSTRUCTIONS IN040–06 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 INTRODUCTION – REPAIR INSTRUCTIONS 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 INTRODUCTION – FOR ALL OF VEHICLES FOR ALL OF VEHICLES IN0HV–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 INTRODUCTION – FOR ALL OF VEHICLES 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 Pub.
Page 16 IN–11 INTRODUCTION – FOR ALL OF VEHICLES 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 INTRODUCTION – FOR ALL OF VEHICLES 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 INTRODUCTION – FOR ALL OF VEHICLES 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 INTRODUCTION – FOR ALL OF VEHICLES 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.
Page 20 IN–15 INTRODUCTION – FOR ALL OF VEHICLES 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 INTRODUCTION – FOR ALL OF VEHICLES 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 INTRODUCTION – FOR ALL OF VEHICLES 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 IN–18 INTRODUCTION – FOR ALL OF VEHICLES FOR VEHICLES EQUIPPED WITH TRACTION CON- TROL (TRC) & VEHICLE STABILITY CONTROL (VSC) SYSTEM NOTICE: When replacing the steering angle sensor or ECU, or when adjusting the front wheel alignment or steering wheel center point in accordance with the removing and installing or replacing the suspension, axle, or steering parts, make sure to perform the steering angle sensor zero point calibration (See page...
Page 24 IN–19 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN00Z–45 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 25: How To Troubleshoot Ecu Controlled Systems
IN–20 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN06D–10 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 26 IN–21 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 27 IN–22 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the AVENSIS/CORONA fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting.
Page 28 IN–23 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 29 IN–24 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 30 IN–25 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs.
Page 31 IN–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 32 IN–27 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 33 IN–28 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 34 IN–29 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 35: How To Use The Diagnostic Chart
IN–30 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN011–38 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 36 IN–31 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 37 IN–32 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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 38 IN–33 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the voltage. Fig. 4 In a circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. Sensor As shown in Fig.
Page 39 IN–34 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED 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. In the case of Fig. 7: Sensor Between terminal 1 of connector ”A”...
Page 40: Terms
IN–35 INTRODUCTION – TERMS TERMS IN044–12 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 41 IN–36 INTRODUCTION – TERMS 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 42 Special Service Tools 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 Stability Control Vacuum Switching Valve...
Page 43 IN–38 INTRODUCTION – TERMS Second Two Wheel Drive Vehicle (4x2) Four Wheel Drive Vehicle (4x4) AVENSIS/CORONA SUP (RM781E)
Page 44 PREPARATION CLUTCH ....... . PP–1 MANUAL TRANSAXLE (C50, C250) ..PP–3 MANUAL TRANSAXLE (E351) .
Page 46 PP–1 PREPARATION – CLUTCH CLUTCH PP119–02 SST (Special Service Tools) 09023–00100 Union Nut Wrench 10 mm Clutch line 09249–63010 Torque Wrench Adaptor Clutch line 09301–00120 Clutch Guide Tool 09301–00210 Clutch Guide Tool 09333–00013 Clutch Diaphragm Spring Aligner 09922–10010 Variable Open Wrench Clutch accumulator AVENSIS/CORONA SUP (RM781E)
Page 47 PP–2 PREPARATION – CLUTCH PP11A–02 RECOMMENDED TOOLS Pin Punch . Reservoir tank 09031–00030 Snap Ring Pliers . 09905–00013 AVENSIS/CORONA SUP (RM781E)
Page 48 5th Driven Gear Replacer 09316–60011 Transmission & Transfer Bearing Output shaft rear ball bearing Replacer (09316–00021) Replacer ”A” 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32111) Side Bearing Race Replacer Differential case oil seal Handle (09351–32130) Oil Seal Replacer Differential case oil seal (09351–32150)
Page 49 PP–4 PREPARATION – MANUAL TRANSAXLE (C50, C250) 09608–03071 Replacer Input shaft rear ball bearing 09612–65014 Steering Worm Bearing Puller Input shaft front bearing Differential side bearing outer race 09628–62011 Ball Joint Puller 5th driven gear 09636–20010 Upper Ball Joint Dust Cover No.3 hub sleeve assembly Replacer Bearing Remover...
Page 50 PP–5 PREPARATION – MANUAL TRANSAXLE (C50, C250) (09951–00460) Replacer 46 Input shaft front bearing Differential side bearing (09951–00620) Replacer 62 Output shaft front bearing 09950–60020 Replacer Set No.2 (09951–00680) Replacer 68 Differential side bearing outer race (Transaxle case side) Replacer 71 Differential side bearing outer race (09951–00710) (Transmission case side)
Page 51 PP–6 PREPARATION – MANUAL TRANSAXLE (C50, C250) PP04O–03 RECOMMENDED TOOLS Torque Wrench (30 kgf–cm) Differential preload 09025–00010 Pin Punch . 09031–00030 09040–00011 Hexagon Wrench Set . 09042–00010 Torx Socket T30 . 09905–00012 Snap Ring No.1 Expander . AVENSIS/CORONA SUP (RM781E)
Page 52 PP–7 PREPARATION – MANUAL TRANSAXLE (C50, C250) PP04Q–01 EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Magnetic finger AVENSIS/CORONA SUP (RM781E)
Page 53 PP–8 PREPARATION – MANUAL TRANSAXLE (C50, C250) PP04S–01 LUBRICANT Item Capacity Classification Manual transaxle oil Manual transaxle oil API GL–4 or GL–5 API GL 4 or GL 5 1 9 liters (2 0 US qts 1 7 lmp qts) 1.9 liters (2.0 US qts, 1.7 lmp.qts) (w/ Differential oil) SAE 75W–90 AVENSIS/CORONA SUP (RM781E)
Page 54 PP–9 PREPARATION – MANUAL TRANSAXLE (C50, C250) PP11C–02 SSM (Special Service Materials) Seal Packing 1281, Transmission case x Transaxle case 08826–00090 THREE BOND 1281 or equivalent Transmission case x Case cover (FIPG) Adhesive 1344 Transmission case cover bolt 08833–00080 THREE BOND 1344 Straight screw plug LOCTITE 242 or equivalent Control shaft cover bolt...
Page 55 PP–10 PREPARATION – MANUAL TRANSAXLE (E351) MANUAL TRANSAXLE (E351) PP3D3–01 SST (Special Service Tools) 09223–15020 Oil Seal & Bearing Replacer Differential case oil seal 09308–00010 Oil Seal Puller Output shaft front bearing outer race Transfer Bearing Replacer Differential case tapered roller 09316–20011 bearing 09316–60011...
Page 56 PP–11 PREPARATION – MANUAL TRANSAXLE (E351) 09612–65014 Steering Worm Bearing Puller Input shaft bearing Differential case tapered roller bearing outer race 09950–00020 Bearing Remover Bearing Remover Attachment Output shaft front bearing 09950–00030 09950–30011 Puller A Set 5th driven gear No.3 clutch hub 09950–40011 Puller B Set Differential case tapered roller bearing...
Page 57 PP–12 PREPARATION – MANUAL TRANSAXLE (E351) (09951–07150) Handle 150 AVENSIS/CORONA SUP (RM781E)
Page 58 Pin Punch . 09040–00011 Hexagon Wrench Set . 09042–00040 Torx Socket T50 . Torx Socket T45 . 09042–00050 09082–00040 TOYOTA Electrical Tester. 09258–00030 Hose Plug Set . 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . AVENSIS/CORONA SUP (RM781E)
Page 59 PP–14 PREPARATION – MANUAL TRANSAXLE (E351) PP0VE–02 EQUIPMENT Dial indicator with magnetic base Feeler gauge Magnetic finger Micrometer Plastigage Precision straight edge Torque wrench Vise AVENSIS/CORONA SUP (RM781E)
Page 60 PP–15 PREPARATION – MANUAL TRANSAXLE (E351) PP0VF–05 LUBRICANT Item Capacity Classification API GL–4 or GL–5 Manual transaxle oil (w/ Differential oil) 2.5 liters (2.6 US qts, 2.2 Imp. qts) SAE 75W–90 AVENSIS/CORONA SUP (RM781E)
Page 61 Transmission & Transfer Bearing Replacer (09316–00011) Replacer Pipe 3rd driven gear Differential side bearing (09316–00041) Replacer ”C” Output shaft thrust washer TOYOTA Automatic Transmission 09350–32014 Tool Set (09351–32120) Overdrive Bearing Replacer Differential side bearing Handle Differential side bearing (09351–32130) retainer oil seal...
Page 62 PP–17 PREPARATION – MANUAL TRANSAXLE (S54, S55) 09608–00081 Differential Side Bearing Cone Input shaft front oil seal Replacer 09612–22011 Tilt Handle Bearing Replacer Output shaft rear bearing No.3 clutch hub Bearing Remover 09950–00020 09950–00030 Bearing Remover Attachment 09950–30011 Puller A Set No.
Page 63 PP–18 PREPARATION – MANUAL TRANSAXLE (S54, S55) PP11D–02 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) Differential preload 09031–00030 Pin Punch . 09040–00011 Hexagon Wrench Set . 09905–00012 Snap Ring No.1 Expander . AVENSIS/CORONA SUP (RM781E)
Page 64 PP–19 PREPARATION – MANUAL TRANSAXLE (S54, S55) PP0H4–01 EQUIPMENT Dial indicator Torque wrench Feeler gauge Magnetic finger Micrometer AVENSIS/CORONA SUP (RM781E)
Page 65 PP–20 PREPARATION – MANUAL TRANSAXLE (S54, S55) PP0H5–02 LUBRICANT Item Capacity Classification Manual transaxle oil API GL–4 or GL–5 2.2 liters (2.3 US qts, 1.9 lmp. qts) (w/ Differential oil) SAE 75W–90 AVENSIS/CORONA SUP (RM781E)
Page 66 PP–21 PREPARATION – MANUAL TRANSAXLE (S54, S55) PP11E–02 SSM (Special Service Materials) 08826–00090 Seal Packing 1281, Transmission case x Transaxle case THREE BOND 1281 or equivalent Transmission case x Case cover (FIPG) 08833–00070 Adhesive 1324, Rear bearing retainer set bolt THREE BOND 1324 or equivalent 08833–00080 Adhesive 1344...
Page 67 PP–22 PREPARATION – AUTOMATIC TRANSAXLE (A246E) AUTOMATIC TRANSAXLE (A246E) PP2J6–02 SST (Special Service Tools) 09308–00010 Oil Seal Puller 09350–32014 TOYOTA Automatic Transmission Tool Set One–way Clutch Test Tool (09351–32010) (09351–32020) Stator Stopper (09351–32111) Side Bearing Race Replacer (09351–32130) Handle Oil Seal Replacer (09351–32150)
Page 68 PP–23 PREPARATION – AUTOMATIC TRANSAXLE (A246E) PP2J7–02 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. AVENSIS/CORONA SUP (RM781E)
Page 69 PP–24 PREPARATION – AUTOMATIC TRANSAXLE (A246E) PP2J8–01 EQUIPMENT Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Straight edge Torque converter Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 70 PP–25 PREPARATION – AUTOMATIC TRANSAXLE (A246E) PP0IP–02 LUBRICANT Item Capacity Classification Automatic transmission fluid Dry fill 7.6 liters (8.0 US qts, 6.7 lmp. qts) ATF D–ll or DEXRON® lll (DEXRON® ll) Drain and refill 3.1 liters (3.3 US qts, 2.7 lmp. qts) AVENSIS/CORONA SUP (RM781E)
Page 71 PP–26 PREPARATION – AUTOMATIC TRANSAXLE (A246E) PP2J9–01 SSM (Special Service Materials) 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent AVENSIS/CORONA SUP (RM781E)
Page 72 – AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE (U240E) PP2J6–03 SST (Special Service Tools) 09223–00010 Cover & Seal Replacer 09308–00010 Oil Seal Puller TOYOTA Automatic Transmission 09350–32014 Tool Set (09351–32010) One–way Clutch Test Tool (09351–32020) Stator Stopper (09351–32130) Handle Oil Seal Replacer (09351–32150)
Page 73 PP–28 PREPARATION – AUTOMATIC TRANSAXLE (U240E) PP2J7–03 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. AVENSIS/CORONA SUP (RM781E)
Page 74 PP–29 PREPARATION – AUTOMATIC TRANSAXLE (U240E) PP2J8–01 EQUIPMENT Vernier calipers Torque converter Dial indicator or dial indicator with magnetic base Drive plate Straight edge Torque converter Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 75 PP–30 PREPARATION – AUTOMATIC TRANSAXLE (U240E) PP0IP–03 LUBRICANT Item Capacity Classification Automatic transmission fluid Dry fill 7.4 liters (7.8 US qts, 6.5 lmp. qts) ATF Type T–IV Drain and refill 4.1 liters (4.3 US qts, 3.6 lmp. qts) AVENSIS/CORONA SUP (RM781E)
Page 76 PP–31 PREPARATION – AUTOMATIC TRANSAXLE (U240E) PP2J9–01 SSM (Special Service Materials) 08833–00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent AVENSIS/CORONA SUP (RM781E)
Page 77 PP–32 PREPARATION – SUSPENSION AND AXLE SUSPENSION AND AXLE PP3CN–01 SST (Special Service Tools) 09240–00020 Wire Gauge Set Front drive shaft 09506–35010 Differential Drive Pinion Rear Front drive shaft Bearing Replacer Drive Shaft Remover Attachment Front drive shaft 09520–01010 09520–24010 Differential Side Gear Shaft Front drive shaft Puller...
Page 78 PP–33 PREPARATION – SUSPENSION AND AXLE 09950–60010 Replacer Set (09951–00640) Replacer 64 Front axle Front drive shaft Handle Set 09950–70010 (09951–07150) Handle 150 Front axle Front drive shaft AVENSIS/CORONA SUP (RM781E)
Page 79 PP–34 PREPARATION – SUSPENSION AND AXLE PP3CO–01 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) 09905–00012 Snap Ring No.1 Expander . 09905–00013 Snap Ring Pliers . AVENSIS/CORONA SUP (RM781E)
Page 80 PP–35 PREPARATION – SUSPENSION AND AXLE PP11I–03 EQUIPMENT Dial indicator Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 81 PP–36 PREPARATION – SUSPENSION AND AXLE PP11J–03 LUBRICANT Item Capacity Application Outboard joint grease Color=Black 85 – 105 g (3.00 – 3.70 oz.) Inboard joint grease Color=Yellow 125.5 – 135.5 g (4.43 – 4.78 oz.) AVENSIS/CORONA SUP (RM781E)
Page 82 PP–37 PREPARATION – STEERING STEERING PP2JE–03 SST (Special Service Tools) 09023–12700 Union Nut Wrench 17mm PS vane pump (1ZZ–FE, 3ZZ–FE) 09249–63010 Torque Wrench Adaptor PS vane pump (1AZ–FSE) Power Steering Pressure Gauge Power steering fluid 09640–10010 (09641–01010) Gauge Assy (09641–01030) Attachment B (09641–01060) Attachment E...
Page 83 PP–38 PREPARATION – STEERING PP2JF–03 RECOMMENDED TOOLS 09025–00010 Torque Wrench (30 kgf–cm) PS vane pump AVENSIS/CORONA SUP (RM781E)
Page 84 PP–39 PREPARATION – STEERING PP0J9–11 EQUIPMENT Caliper gauge PS vane pump Vernier Calipers PS vane pump Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 85 PP–40 PREPARATION – STEERING PP18M–03 LUBRICANT Item Capacity Classification Power steering fluid 0.8 liters (0.9 US qts, 0.7 Imp.qts) ATF DEXRON® II or III (Total) AVENSIS/CORONA SUP (RM781E)
Page 86 PP–41 PREPARATION – BODY ELECTRICAL BODY ELECTRICAL PP090–04 RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set. AVENSIS/CORONA SUP (RM781E)
Page 87 PP–42 PREPARATION – BODY ELECTRICAL PP091–04 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead AVENSIS/CORONA SUP (RM781E)
Page 88 PP–43 PREPARATION – BODY BODY PP0M7–02 EQUIPMENT Clip remover Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 89 PP–44 PREPARATION – AIR CONDITIONING AIR CONDITIONING PP3D0–01 SST (Special Service Tools) 07110–58060 Air Conditioner Service Tool Set (07117–58060) Refrigerant Drain Service Valve T–Joint (07117–58070) (07117–58080) Quick Disconnect Adapter High pressure side (07117–58090) Quick Disconnect Adapter Low pressure side (07117–88060) Refrigerant Charging Hose High pressure side (Color: Red)
Page 90 PP–45 PREPARATION – AIR CONDITIONING PP3D1–01 RECOMMENDED TOOLS 09082–00040 TOYOTA Electrical Tester. AVENSIS/CORONA SUP (RM781E)
Page 91 PP–46 PREPARATION – AIR CONDITIONING PP095–05 EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Torque wrench AVENSIS/CORONA SUP (RM781E)
Page 92 PP–47 PREPARATION – AIR CONDITIONING PP096–02 LUBRICANT Item Capacity Classification Compressor oil – ND–OIL 8 or equivalent AVENSIS/CORONA SUP (RM781E)
Page 94 SERVICE SPECIFICATIONS STANDARD BOLT ......SS–1 CLUTCH ....... . SS–4 MANUAL TRANSAXLE (C50, C250) .
Page 96 SS–1 SERVICE SPECIFICATIONS – STANDARD BOLT 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 AVENSIS/CORONA SUP (RM781E)
Page 97 SS–2 SERVICE SPECIFICATIONS – STANDARD BOLT 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 98 SS–3 SERVICE SPECIFICATIONS – STANDARD BOLT SS0ZU–01 HOW TO DETERMINE NUT STRENGTH Nut Type Present Standard Old Standard Hexagon Nut 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 99 SS–4 SERVICE SPECIFICATIONS – CLUTCH CLUTCH SS02L–03 SERVICE DATA Pedal height from asphalt sheet 3ZZ–FE LHD 139.7 – 149.7 mm (5.500 – 5.894 in.) 144.3 – 154.3 mm (5.681 – 6.075 in.) 1ZZ–FE Engine LHD 139.7 – 149.7 mm (5.500 – 5.894 in.) 144.3 –...
Page 100 SS–5 SERVICE SPECIFICATIONS – CLUTCH SS02M–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Clutch line union Master cylinder installation nut Master cylinder x Clutch accumulator 1CD–FTV Engine RHD 32 (44) 330 (450) 24 (33) Clutch cover x Flywheel Release fork support 1ZZ–FE, 3ZZ–FE Engine Others Engine ( ): For use without SST...
Page 101 SS–6 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (C50, C250) MANUAL TRANSAXLE (C50, C250) SS02P–06 SERVICE DATA Input shaft roller bearing journal diameter Min. 24.985 mm (0.9834 in.) Input shaft 3rd gear journal diameter Min. 30.985 mm (1.2199 in.) Input shaft 4th gear journal diameter Min.
Page 102 SS–7 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (C50, C250) Input shaft snap ring thickness Input shaft snap ring thickness No.2 clutch hub No.2 clutch hub Mark 0 2.30 mm (0.0906 in.) Mark 0 2.30 mm (0.0906 in.) Mark 1 Mark 1 2.36 mm (0.0929 in.) 2.36 mm (0.0929 in.) Mark 2...
Page 103 SS–8 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (C50, C250) Differential side bearing adjusting shim thickness Differential side bearing adjusting shim thickness Mark A Mark A 2 10 mm (0 0827 in ) 2.10 mm (0.0827 in.) Mark B Mark B 2 15 mm (0 0846 in ) 2.15 mm (0.0846 in.) Mark C Mark C...
Page 104 SS–9 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (C50, C250) SS02Q–07 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Clutch release cylinder x Transaxle Starter x Transaxle Transaxle x Engine Transaxle x Engine Stiffener plate set bolt (See page MX–3) Bolt B Bolt A Engine left mounting bracket x Transaxle Engine left mounting bracket x Transaxle Bolt A...
Page 105 SS–10 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E351) MANUAL TRANSAXLE (E351) SS0G6–06 SERVICE DATA Input shaft 3rd & 4th gear journal diameter Min. 35.984 mm (1.4167 in.) 5th gear journal diameter Min. 27.957 mm (1.1007 in.) Runout Max. 0.03 mm (0.0012 in.) Output shaft 1st gear journal diameter Min.
Page 106 SS–11 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E351) 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 107 SS–12 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E351) 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 108 SS–13 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E351) SS0G7–08 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 109 SS–14 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (E351) Reverse shift arm bracket assembly x Transaxle case Transaxle case receiver x Transaxle case 65 in.·lbf Clutch release fork support Control cable bracket x Transaxle case Vehicle speed sensor Clutch release line bracket x Transaxle case Back–up light switch Filler and drain plugs No.1 and No.2 oil receiver pipes x Transmission case...
Page 110 SS–15 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S54, S55) MANUAL TRANSAXLE (S54, S55) SS09M–04 SERVICE DATA Input shaft roller bearing journal diameter Min. 29.987 mm (1.181 in.) Input shaft 3rd gear journal diameter Min. 33.100 mm (1.3031 in.) Input shaft 4th gear journal diameter Min.
Page 111 SS–16 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S54, S55) Input shaft snap ring thickness In ut shaft sna ring thickness No.2 clutch hub No.2 clutch hub Mark 1 1.95 – 2.00 mm (0.0768 – 0.0787 in.) Mark 1 1.95 2.00 mm (0.0768 0.0787 in.) Mark 2 2.00 –...
Page 112 SS–17 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S54, S55) SS09N–05 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Starter x Transaxle Clutch release cylinder x Transaxle Clutch line bracket x Transaxle (See page MX–3) Bolt A Bolt B 43 in.·lbf Engine left mounting bracket x Transaxle Engine left mounting bracket x Insulator Transaxle x Engine (See page MX–3) Upper bolt...
Page 113 SS–18 SERVICE SPECIFICATIONS – MANUAL TRANSAXLE (S54, S55) Speed sensor lock plate set bolt 48 in.·lbf Clutch release fork support AVENSIS/CORONA SUP (RM781E)
Page 114 SS–19 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A246E) AUTOMATIC TRANSAXLE (A246E) SS0YH–02 SERVICE DATA Line pressure (Wheel locked) Engine idling D range 372 – 441 kPa (3.8 – 4.5 kgf/cm , 54 – 64 psi) R range 598 – 716 kPa (6.1 – 7.3 kgf/cm , 87 –...
Page 115 SS–20 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A246E) Shift schedule (PWR mode) D range 1 → 2 (Throttle valve fully opened) 50 – 58 km/h (31 – 36 mph) 2 → 3 95 – 103 km/h (59 – 64 mph) 3 → 4 151 –...
Page 116 SS–21 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A246E) Shift schedule (NORM mode) D range 1 → 2 (Throttle valve fully opened) 50 – 58 km/h (31 – 36 mph) 2 → 3 95 – 103 km/h (59 – 64 mph) 3 → 4 151 –...
Page 117 SS–22 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (A246E) SS0YI–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Drain plug x Transaxle case Oil pan set bolt 48 in.·lbf Oil strainer set bolt Valve body set bolt Detent spring Neutral start switch x Transaxle case 48 in.·lbf Neutral start switch lock nut 61 in.·lbf...
Page 118 SS–23 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE (U240E) SS18S–02 SERVICE DATA Line pressure (Wheel locked) Engine idling D range 372 – 412 kPa (3.8 – 4.2 kgf/cm , 54 – 59 psi) R range 640 – 742 kPa (6.5 – 7.6 kgf/cm , 93 –...
Page 119 SS–24 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (U240E) Shift schedule (PWR mode) D range 1 → 2 (Throttle valve fully opened) 53 – 60 km/h (33 – 37 mph) 2 → 3 99 – 107 km/h (62 – 66 mph) 3 → 4 154 –...
Page 120 SS–25 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (U240E) Shift schedule (NORM mode) D range 1 → 2 (Throttle valve fully opened) 53 – 60 km/h (33 – 37 mph) 2 → 3 99 – 107 km/h (62 – 66 mph) 3 → 4 154 –...
Page 121 SS–26 SERVICE SPECIFICATIONS – AUTOMATIC TRANSAXLE (U240E) SS0YI–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Input turbine speed sensor x Transaxle case 11.3 Counter gear speed sensor x Transaxle case 11.3 ATF Temperature sensor x Valve body 58 in.·lbf Oil strainer x Valve body 10.8 Oil pan x Transaxle case 69 in.·lbf...
Page 122 SS–27 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SUSPENSION AND AXLE SS0IY–03 SERVICE DATA Drive shaft standard length 943.60 ± 1.0 mm (37.15 ± 0.039 in.) 1ZZ–FE engine (M/T) 657.90 ± 0.8 mm (25.90 ± 0.032 in.) 943.60 ± 1.0 mm (37.15 ± 0.039 in.) 1ZZ–FE engine (A/T) 653.20 ±...
Page 123 SS–28 SERVICE SPECIFICATIONS – SUSPENSION AND AXLE SS0IZ–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT: Steering knuckle x Shock absorber 2,600 Suspension support x Body Suspension support x Piston rod ABS speed sensor set bolt 71 in.·lbf ABS speed sensor wire harness clamp x Shock absorber 48 in.·lbf Flexible hose x Shock absorber bracket AVENSIS/CORONA SUP (RM781E)
Page 124 SS–29 SERVICE SPECIFICATIONS – BRAKE BRAKE SS0FS–06 SERVICE DATA Brake pedal height (from asphalt sheet) 147.0 – 157.0 mm (5.787 – 6.181 in.) 149.5 – 159.5 mm (5.886 – 6.280 in.) Brake pedal freeplay 1 – 6 mm (0.04 – 0.24 in.) Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) LHD Gasoline engine (w/o ABS) More than 70 mm (2.76 in.)
Page 125 SS–30 SERVICE SPECIFICATIONS – STEERING STEERING SS0IF–03 SERVICE DATA POWER STEERING FLUID Oil level rise Maximum 5 mm (0.20 in.) 1ZZ–FE, 3ZZ–FE Engines: Oil pressure at idle speed with valve closed Minimum 8,300 kPa (85 kgf/cm , 1,209 psi) 1AZ–FSE Engine: Oil pressure at idle speed with valve closed Minimum 8,800 kPa (90 kgf/cm , 1,280 psi)
Page 126 SS–31 SERVICE SPECIFICATIONS – STEERING SS0IG–03 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf TILT STEERING COLUMN Steering column assembly set bolt and nut 25.5 Control valve shaft x Yoke Steering wheel set nut Steering wheel pad set screw (Torx screw) 78 in.·lbf POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) Rear housing set bolt...
Page 127 SS–32 SERVICE SPECIFICATIONS – BODY BODY SS0BN–02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf FRONT BUMPER Bumper reinforcement x Body AVENSIS/CORONA SUP (RM781E)
Page 128 SS–33 SERVICE SPECIFICATIONS – AIR CONDITIONING AIR CONDITIONING SS038–06 SERVICE DATA 460 ± 20 g (16.23 ±0.71 oz.) Refrigerant volume AVENSIS/CORONA SUP (RM781E)
Page 129 SS–34 SERVICE SPECIFICATIONS – AIR CONDITIONING SS050–07 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Compressor x Compressor bracket Compressor x Discharge hose Compressor x Suction hose Condenser x Liquid tube 48 in.·lbf Condenser x Discharge hose 48 in.·lbf AVENSIS/CORONA SUP (RM781E)
Page 130 DIAGNOSTICS DIAGNOSTIC TROUBLE CODE CHART ..DI–132 AUTOMATIC TRANSAXLE (A246E) ..DI–1 PARTS LOCATION ......DI–133 HOW TO PROCEED WITH TERMINALS OF ECU...
Page 132 DI–1 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) AUTOMATIC TRANSAXLE (A246E) DI2L4–10 HOW TO PROCEED WITH TROUBLESHOOTING Items inside are titles of pages in this manual, with the Vehicle Brought to Workshop page number indicated in the bottom portion. See the indicated pages for detailed explanations.
Page 133: Automatic Transaxle (A246E
DI–2 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI2L5–04 CUSTOMER PROBLEM ANALYSIS CHECK Transaxle Control Inspector’s System Check Sheet Name Registration No. Customer’s Name Registration Year Frame No. Date Vehicle Odometer Reading Brought In mile Date Problem Occurred How Often Does j Continuous j Intermittent ( times a day) Problem Occur?
Page 134: Pre-Check
DI–3 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI80A–01 PRE–CHECK DIAGNOSIS SYSTEM Description When troubleshooting Euro–OBD vehicles, the only difference from the usual troubleshooting pro- cedure is that you connect an OBD scan tool com- plying with ISO15031–4 or hand–held tester to the vehicle, and read off various data output from the vehicle’s engine and ECT ECU.
Page 135 DI–4 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symp- toms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detec- tion.
Page 136 DI–5 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECT DIAGNOSIS (Normal Mode) Check the CHK ENG. The CHK ENG comes on when the ignition switch is turned ON and the engine is not running. HINT: If the CHK ENG does not light up, troubleshoot the combination meter (See page BE–1).
Page 137 DI–6 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECT DIAGNOSIS (Check Mode) HINT: Hand–held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in the check mode. Check the DTC.
Page 138 DI–7 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Clear the DTC. The following actions will erase the DTC and freezed frame data. Operating an OBD scan tool or hand–held tester to erase the codes (See the OBD scan tool’s instruction book for operating instructions.). PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble.
Page 139 DI–8 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check engine braking. While running in the 2 range and 2nd gear, release the accelerator pedal and check the engine braking effect. Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down–shift.
Page 140 DI–9 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Replace the ATF. Remove the drain plug and drain the fluid. Reinstall the drain plug securely. F00483 With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF Type D–II or DEXRON®III (DEXRON®II) Capacity: 3.1 liters (3.3 US qts, 2.7 Imp.qts) Start the engine and shift the shift lever into all ranges from P to L range and then shift into P range.
Page 141 DI–10 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Return the control shaft lever 2 notches to the N range. Set the shift lever to N range. While holding the shift lever lightly toward the R range side, tighten the shift lever nut. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to...
Page 142 DI–11 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R ranges. NOTICE: Do the test at normal operating ATF temperature 50 –...
Page 143 DI–12 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, and 1st and reverse brake.
Page 144 DI–13 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) HYDRAULIC TEST Measure the line pressure. NOTICE: Do the test at normal operation ATF temperature 50 – 80 °C (122 – 176 °F). The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.
Page 145 DI–14 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) MANUAL SHIFTING TEST HINT: By this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. Disconnect the solenoid wire. Inspect the manual driving operation. Check that the shift and gear positions correspond to the table below.
Page 146: Diagnostic Trouble Code Chart
DI–15 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FQ–05 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and pro- ceed to the page given. DTC No. Check engine Detection Item Trouble Area...
Page 147: Parts Location
DI–16 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) PARTS LOCATION DI1FR–05 No. 1 Solenoid Valve No. 2 Solenoid Valve Neutral Start Switch SLT Solenoid Valve SL Solenoid Valve O/D OFF Indicator LHD: Kick–down Switch DLC3 Stop Light Switch O/D Main Switch Engine and ECT ECU Pattern Select Switch D09911 AVENSIS/CORONA SUP (RM781E)
Page 148: Terminals Of Ecu
DI–17 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI77O–02 TERMINALS OF ECU Engine and ECT ECU Terminals 28 27 D05962 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG ON 9 – 14 LG ↔ BR S1 (E18–8) – E1 (E19–17) 1st or 2nd gear 9 –...
Page 149: Problem Symptoms Table
DI–18 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FT–06 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting.
Page 150 DI–19 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Chapter 2: On–vehicle repair (L : A245E automatic transaxle repair manual Pub. No. RM757E) Symptom Suspect Area See page Does not move in any forward ranges Off–vehicle matrix chart – Does not move in reverse range Off–vehicle matrix chart –...
Page 151 DI–20 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Symptom Suspect Area See page 1. Low coast modulator valve No engine braking (1st ”L” range) 2. Off–vehicle matrix chart – 1. 2nd coast modulator valve No engine braking (2nd ”2” range) 2. Off–vehicle matrix chart –...
Page 152 DI–21 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Chapter 3: Off–vehicle repair (L : A245E automatic transaxle repair manual Pub. No. RM757E) Symptom Suspect Area See page Does not move in any forward ranges Forward clutch (C 1. Direct clutch (C Does not move in reverse range 2.
Page 153 DI–22 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Symptom Suspect Area See page 1. Forward clutch (C 2. 2nd brake (B Slip (2nd) 3. No.1 one–way clutch (F 4. U/D one–way clutch (F 1. Forward clutch (C Slip (3rd) 2. Direct clutch (C 3.
Page 154: Circuit Inspection
DI–23 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI3VC–05 CIRCUIT INSPECTION P0500 Speed Sensor Malfunction The No.1 speed sensor outputs a 4–pulse signal for every revolution of the transaxle output shaft. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit in- side the combination meter, it is then transmitted to the Engine and ECT ECU.
Page 155 DI–24 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Check operation of speedometer. CHECK: Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. Check speedometer circuit.
Page 156 DI–25 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check Engine and ECT ECU (See page IN–30). Replace Engine and ECT ECU. Check and repair ABS system. AVENSIS/CORONA SUP (RM781E)
Page 157 DI–26 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FV–05 Shift Solenoid A/B Malfunction P0750, P0755 (No. 1/No. 2 Solenoid Valve ) SYSTEM DESCRIPTION The Engine and ECT ECU uses signals from the vehicle speed sensor and crankshaft position sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear). Then the Engine and ECT ECU compares the actual gear with the shift schedule in the Engine and ECT ECU memory to detect the mechanical trouble of the shift solenoid valves, the valve body or automatic trans- axle (clutch, brake or gear etc.).
Page 158 DI–27 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check the valve body (See chapter 2 in the problem symptoms table). Repair or replace the valve body. Repair the transaxle (See page AX–28). AVENSIS/CORONA SUP (RM781E)
Page 159 DI–28 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FW–06 P0753,P0758 Shift Solenoid A/B Electrical Malfunc- tion (No. 1/No. 2 Solenoid Valve) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the No. 1 and No. 2 solenoid valves controlled by Engine and ECT ECU.
Page 160 DI–29 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) WIRING DIAGRAM Engine and ECT ECU Transaxle No. 1 Solenoid Valve (RHD)(LHD) No. 2 Solenoid Valve V–W V–W (RHD)(LHD) D10180 INSPECTION PROCEDURE Measure resistance between terminal S1 or S2 of Engine and ECT ECU connec- tor and body ground.
Page 161 DI–30 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check harness and connector between Engine and ECT ECU and automatic transaxle solenoid connector. PREPARATION: Disconnect the solenoid connector from the automatic trans- axle. CHECK: Check harness and connector between the terminal S1 or S2 of Engine and ECT ECU and the terminal S1 or S2 of solenoid connector.
Page 162 DI–31 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check No. 1 or No. 2 solenoid valve. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the solenoid connector. Remove the No. 1 or No. 2 solenoid valve . CHECK: Measure resistance between the solenoid connector and the solenoid body.
Page 163 DI–32 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FX–05 P0770 Shift Solenoid E Malfunction (SL Solenoid Valve) SYSTEM DESCRIPTION The Engine and ECT ECU uses the signals from the throttle position sensor, air–flow meter and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the Engine and ECT ECU compares the engagement Line condition of the lock–up clutch with the lock–up schedule in the...
Page 164 DI–33 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check valve body (See chapter 2 in the problem symptoms table). Repair or replace the valve body. Check torque converter (See page AX–33). Replace the torque converter. Repair the transaxle. AVENSIS/CORONA SUP (RM781E)
Page 165 DI–34 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI1FY–06 P0773 Shift Solenoid E Electrical Malfunction (SL Solenoid Valve) CIRCUIT DESCRIPTION The SL solenoid valve is turned ON and OFF by signals from the Engine and ECT ECU to control the hydrau- lic pressure acting on the lock–up relay valve, then the signals control operation of the lock–up clutch. Fail safe function If the Engine and ECT ECU detects a malfunction, it turns the SL solenoid valve OFF.
Page 166 DI–35 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Measure resistance between terminal SL of Engine and ECT ECU and body ground. PREPARATION: Disconnect the connector from Engine and ECT ECU. CHECK: Measure resistance between the terminal SL of Engine and ECT ECU and the body ground.
Page 167 DI–36 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check SL solenoid valve. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the SL solenoid valve connector. Remove the SL solenoid valve. CHECK: Measure resistance between the terminal SL of shift sole- noid valve and the solenoid body.
Page 168 DI–37 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI80B–01 P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock–up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signals to Engine and ECT ECU. Then the Engine and ECT ECU cancels operation of the lock–up clutch while braking is in progress.
Page 169 DI–38 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Lift Back (LHD): Engine and Stop Light ECT ECU Center J/B Instrument Panel J/B Instrument Panel J/B Switch STOP G–W G–W W–R G–W G–W G–W Block G–W G–W High Mounted G–W MAIN Stop Stop Stop Light Light Light RH...
Page 170 DI–39 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Wagon: Engine and Stop Light ECT ECU Instrument Panel J/B Center J/B Switch STOP W–R * G–W G–W J16 * G–W G–W J34 * Block J17 * J35 * High G–W G–W G–W Mounted MAIN Stop Stop...
Page 171 DI–40 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE HINT: Read freeze frame data using hand–held tester. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was run- ning or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc.
Page 172 DI–41 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check harness and connector between Engine and ECT ECU and stop light switch (See page IN–30). Repair or replace harness or connector. Check and replace Engine and ECT ECU (See page IN–30). AVENSIS/CORONA SUP (RM781E)
Page 173 DI–42 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI61W–05 P1760 Linear Solenoid for Line Pressure Control Circuit malfunction (SLT Solenoid Valve) CIRCUIT DESCRIPTION The throttle pressure that is applied to the primary regulator valve (which modulates line pressure) causes the SLT solenoid Line Pressure Con- valve, under electronic control, to precisely and minutely modu- trol Pressure...
Page 174 DI–43 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) WIRING DIAGRAM Engine and ECT ECU Transaxle LG–B LG–B IE2 IF2 (RHD) (LHD) Solenoid Valve P–B P–B – IE2 IF2 (RHD) (LHD) D10182 AVENSIS/CORONA SUP (RM781E)
Page 175 DI–44 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Check SLT solenoid valve. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the solenoid connector. Check solenoid resistance: CHECK: Measure resistance between terminals 1 and 2 of solenoid con- nector. Resistance: 5.0 –...
Page 176 DI–45 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI80C–01 P1780 Neutral Start Switch Malfunction CIRCUIT DESCRIPTION The neutral start switch detects the shift lever range and sends the signals to the Engine and ECT ECU. The Engine and ECT ECU receives the signals (NSW, R, 2 and L) from the neutral start switch, when the signal is not sent to the Engine and ECT ECU from the neutral start switch, the Engine and ECT ECU judges that the shift lever is in the D range.
Page 177 DI–46 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) WIRING DIAGRAM Engine and ECT ECU Neutral Start Switch Y–G R–L Center J/B R–B R–B Center J/B B–W B–W 20 3E W–B B–W Center J/B Instrument Panel J/B Ignition Switch GAUGE R–L B–Y IG1 AM1 Instrument Panel J/B Instrument Panel J/B W–R...
Page 178 DI–47 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Read NSW, REVERSE, 2ND and LOW signals. When using hand–held tester: PREPARATION: Connect the hand–held tester to the DLC3. Turn the ignition switch ON. CHECK: Shift the shift lever to the P, R, N, 2 and L ranges, and read the NSW, REVERSE, 2ND and LOW signals on the hand–held tes- ter.
Page 179 DI–48 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check neutral start switch. PREPARATION: Jack up the vehicle. Remove the neutral start switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each range. Shift Range Terminal No. to continuity –...
Page 180 DI–49 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI80D–01 O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT INSPECTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed once again. In O/D main switch OFF position, the O/D OFF indicator light lights up, and the Engine and ECT ECU prohibits shifting to O/D.
Page 181 DI–50 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE O/D OFF indicator light does not light up Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between the terminals 2 and 4 of the O/D main switch connector.
Page 182 DI–51 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check OVERDRIVE CUT SW2 signal. When using hand–held tester: PREPARATION: Connect a hand–held tester to the DLC3. Turn the ignition switch ON and the hand–held tester main switch ON. CHECK: Read the OVERDRIVE CUT SW2 signal on the hand–held tes- ter.
Page 183 DI–52 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check harness and connector between O/D OFF indicator light and Engine and ECT ECU (See page IN–30). PREPARATION: Disconnect the connector (E6) of Engine and ECT ECU and the connector (C14) of the combination meter. CHECK: Measure the continuity between the connector (E6) of Engine and ECT ECU and the connector (C14) of the combination me-...
Page 184 DI–53 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) O/D OFF indicator light remains ON Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between the terminals 2 and 4 of O/D main switch connector. O/D main switch Resistance No continuity Q08078...
Page 185 DI–54 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI336–03 Pattern Select Switch Circuit CIRCUIT DESCRIPTION The Engine & ECT ECU memory contains the shift programs for the NORMAL, POWER and SNOW (w/ SNOW mode) patterns, 2 range, L range and the lock–up patterns. By following the programs corresponding to the signals from the pattern select switch, the neutral start switch and other various sensors, the Engine &...
Page 186 DI–55 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Check PATTERN SEL SW signal. When using hand–held tester: PREPARATION: Remove the DLC3 cover. Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON. CHECK: Read the PATTERN SEL SW signal on the hand–held tester.
Page 187 DI–56 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check pattern select switch PREPARATION: Disconnect the pattern select switch connector. CHECK: Check continuity between terminals 2 and 3 (PWR, NORM), 3 and 5 (SNOW) of pattern select switch connector when the se- lect switch is set to PWR, NORM or SNOW position. Switch position Tester connection Specified condition...
Page 188 DI–57 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) DI80E–01 Kick–down Switch Circuit (LHD) CIRCUIT DESCRIPTION The kick–down switch is turned ON when the accelerator pedal is depressed beyond the full throttle opening and sends signals to Engine and ECT ECU. When the kick–down switch is turned ON, the Engine and ECT ECU controls gear shifting according to the programmed shift diagrams.
Page 189 DI–58 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) INSPECTION PROCEDURE Check KICK DOWN SW signal. When using hand–held tester: PREPARATION: Remove the DLC3 cover. Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON. CHECK: Read the KICK DOWN SW signal on the hand–held tester.
Page 190 DI–59 DIAGNOSTICS – AUTOMATIC TRANSAXLE (A246E) Check kick–down switch. PREPARATION: Disconnect the kick–down switch connector. CHECK: Check continuity at each terminal of kick–down switch connec- tor. Kick–down Switch Specified continuity Continuity D01519 No continuity Replace kick–down switch Check harness and connector between Engine & ECT ECU and kick–down switch, kick–down switch and body ground (See page IN–30).
Page 191 DI–60 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE (U240E) DI2L4–11 HOW TO PROCEED WITH TROUBLESHOOTING Vehicle Brought to Workshop are titles of pages in this manual, with the Items inside page number indicated in the bottom portion. See the indicated pages for detailed explanations.
Page 192: Automatic Transaxle (U240E
DI–61 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI2L5–06 CUSTOMER PROBLEM ANALYSIS CHECK Automatic Transaxle Inspector’s System Check Sheet Name Registration No. Customer’s Name Registration Year Frame No. Date Vehicle Odometer Reading Brought In mile Date Problem Occurred How Often Does Intermittent ( times a day) Continuous Problem Occur?
Page 193: Pre-Check
DI–62 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI80F–01 PRE–CHECK DIAGNOSIS SYSTEM Description When troubleshooting Euro–OBD vehicles, the only difference from the usual troubleshooting pro- cedure is that you connect an OBD scan tool com- plying with ISO15031–4 or hand–held tester to the vehicle, and read off various data output from the vehicle’s engine and ECT ECU.
Page 194 DI–63 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symp- toms and perform troubleshooting. Most DTCs use 2 trip detection logic(*) to prevent erroneous detec- tion.
Page 195 DI–64 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECT DIAGNOSIS (Normal Mode) Check the CHK ENG. The CHK ENG comes on when the ignition switch is turned ON and the engine is not running. HINT: If the CHK ENG does not light up, troubleshoot the combination meter (See page BE–1).
Page 196 DI–65 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECT DIAGNOSIS (Check Mode) HINT: Hand–held tester only: Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in Normal mode can also be detected in the check mode. Check the DTC.
Page 197 DI–66 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Clear the DTC. The following actions will erase the DTC and freezed frame data. Operating an OBD scan tool or hand–held tester to erase the codes (See the OBD scan tool’s instruction book for operating instructions.). PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble.
Page 198 DI–67 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down–shift. L range test Shift into the L range and fully depress the accelerator pedal and check the following points: Check no up–shift.
Page 199 DI–68 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Replace the ATF. Remove the drain plug and drain the fluid. Reinstall the drain plug securely. D07261 With the engine OFF add new fluid through the oil filler pipe. Fluid type: ATF Type T–IV Capacity: 4.1 liters (4.3 US qts, 3.6 Imp.qts) Start the engine and shift the shift lever into all ranges from P to L range and then shift into P range.
Page 200 DI–69 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Return the control shaft lever 2 notches to N range. Set the shift lever to N range. While holding the shift lever lightly toward the R range side, tighten the shift lever nut. Torque: 13 N·m (130 kgf·cm, 9 ft·lbf) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D range and reverses when shifting it to the R...
Page 201 DI–70 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) MECHANICAL SYSTEM TESTS Measure the stall speed. The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R ranges. NOTICE: Do the test at normal operating ATF temperature 50 –...
Page 202 DI–71 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Measure the time lag. When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch, and 1st &...
Page 203 DI–72 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) HYDRAULIC TEST Measure the line pressure. NOTICE: Do the test at normal operation ATF temperature 50 – 80 °C (122 – 176 °F). The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.
Page 204 DI–73 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) MANUAL SHIFTING TEST HINT: By this test, it can be determined whether the trouble is within the electrical circuit or is a mechanical problem in the transaxle. Disconnect the solenoid wire. Inspect the manual driving operation. Check that the shift and gear positions correspond to the table below.
Page 205: Diagnostic Trouble Code Chart
DI–74 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RF–03 DIAGNOSTIC TROUBLE CODE CHART If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and pro- ceed to the page given. DTC No. Check engine Detection Item Trouble Area...
Page 206 DI–75 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) *1: ”f” mark means Check engine warning light blinks once every 2 seconds. ”X” mark means Check engine warning light never blinks. *2: ”f” mark means Engine and ECT ECU memorizes the malfunction code if the Engine and ECT ECU detects the DTC detection condition.
Page 207: Parts Location
DI–76 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6TF–03 PARTS LOCATION Counter Gear Speed Sensor SLT Solenoid Valve Input Turbine Speed Sensor ATF Temperature Sensor SL1 Solenoid Valve Neutral Start Switch DSL Solenoid Valve S4 Solenoid Valve SL2 Solenoid Valve O/D OFF Indicator LHD: Kick–down Switch DLC3...
Page 208: Terminals Of Ecu
DI–77 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RG–03 TERMINALS OF ECU D01054 D03442 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG ON and brake pedal depressed 10 – 14 STP (E13 22) ↔ E1 (E16 3) STP (E13–22) ↔ E1 (E16–3) G W ↔...
Page 209 DI–78 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) IG ON and vehicle stationary Below 1 SPD (E13–6) ↔ E1 (E16–3) G ↔ BR Pulse signal is output IG ON and turn one front wheel slowly Below 1 ↔ 4 –6 IG ON and pattern select switch: PWR 9 –...
Page 210: Problem Symptoms Table
DI–79 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RH–03 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting.
Page 211 DI–80 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Chapter 2: On–vehicle repair (L: U240E automatic transaxle repair manual Pub. No. RM740U) Symptom Suspect Area See page 1. Manual valve Vehicle does not move in any forward range and reverse range 2. Primary regulator valve 3.
Page 212 DI–81 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Chapter 3: Off–vehicle repair (L: U240E automatic transaxle repair manual Pub. No. RM740U) Symptom Suspect Area See page 1. Front and rear planetary gear 2. U/D planetary gear Vehicle does not move in any forward range and reverse range 3.
Page 213: Circuit Inspection
DI–82 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RI–03 CIRCUIT INSPECTION P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The ABS ECU output the vehicle speed signals to a speedometer in the combination meter, and the signals it is then transmitted to the Engine and ECT ECU. The Engine and ECT ECU determines the vehicle speed based on the frequency of these pulse signals.
Page 214 DI–83 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check operation of speedometer. HINT: Read freeze frame data using hand–held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was run- ning or stopped, the engine was warmed up or not, the air–fuel ratio was lean or rich, etc.
Page 215 DI–84 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check voltage between terminal SPD of Engine and ECT ECU connector and body ground. PREPARATION: Turn ignition switch ON. CHECK: Measure voltage between terminal SPD of Engine and ECT ECU connector and body ground. Voltage: 9 –...
Page 216 DI–85 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI80G–01 P0710 Transmission Fluid Temperature Sensor Malfunction (ATF Temperature Sensor) P0711 Transmission Fluid Temperature Circuit Range/Performance problem (Europe only) CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the Engine and ECT ECU.
Page 217 DI–86 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check ATF temperature sensor. PREPARATION: Disconnect the solenoid wire connector. Remove the oil pan. Disconnect all solenoid valve connectors. Remove the transmission wire harness. CHECK: Measure resistance between terminals 1 and 6 of solenoid con- nector at 25 °C (77 °F) and 110 °C (230 °F).
Page 218 DI–87 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI4ZZ–05 P0750 Shift Solenoid A Malfunction (SL1 Solenoid Valve) (Europe only) P0755 Shift Solenoid B Malfunction (SL2 Solenoid Valve) (Europe only) P0765 Shift Solenoid D Malfunction (S4 Solenoid Valve) (Europe only) SYSTEM DESCRIPTION The Engine and ECT ECU uses signals from the vehicle speed sensor to detect the actual gear position (1st, 2nd, 3rd or O/D gear).
Page 219 DI–88 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check SL1, SL2 or S4 solenoid valve operation. PREPARATION: SL1 and SL2 solenoid valve Jack up the vehicle. Remove the oil pan. Remove the SL1, SL2 or S4 solenoid valve. Check Solenoid Resistance: CHECK: SL1 or SL2 solenoid valve: Measure resistance between terminals 1 and 2 of sole-...
Page 220 DI–89 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RY–03 P0753 Shift Solenoid A Electrical Malfunction (SL1 Solenoid Valve) P0758 Shift Solenoid B Electrical Malfunction (SL2 Solenoid Valve) P0768 Shift Solenoid D Electrical Malfunction (S4 Solenoid Valve) CIRCUIT DESCRIPTION Shifting from 1st to O/D is performed in combination with ON and OFF of the SL1 and SL2 solenoid valves controlled by Engine and ECT ECU.
Page 221 DI–90 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Fail safe function: If either of the shift solenoid valve circuits develops an open or short, the Engine and ECT ECU turns the other solenoid ON and OFF to shift to the gear positions shown in the table below. The Engine and ECT ECU also turns the DSL solenoid valve OFF at the same time.
Page 222 DI–91 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Engine and ECT ECU Automatic Transaxle SL1 Solenoid Valve – – SL2 Solenoid Valve – – S4 Solenoid Valve D10189 AVENSIS/CORONA SUP (RM781E)
Page 223 DI–92 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Measure resistance between terminals of Engine and ECT ECU. PREPARATION: Disconnect the connector from Engine and ECT ECU. CHECK: – Measure resistance between terminals SL1 and SL1 Engine and ECT ECU connector. –...
Page 224 DI–93 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Measure harness and connector between Engine and ECT ECU and automatic transaxle solenoid connector. PREPARATION: Disconnect the solenoid connector from the automatic transaxle. Disconnect the connector from the Engine and ECT ECU. CHECK: Measure the harness and connector between terminal –...
Page 225 DI–94 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check SL1, SL2 or S4 solenoid valve. PREPARATION: SL1 and SL2 solenoid valve Jack up the vehicle. Remove the oil pan. Remove the SL1, SL2, or S4 solenoid valve. Check Solenoid Resistance: CHECK: SL1 or SL2 solenoid valve: Measure resistance between terminals 1 and 2 of sole- noid connector.
Page 226 DI–95 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI4ZX–05 P0770 Shift Solenoid E Malfunction (DSL Solenoid Valve) (Europe only) SYSTEM DESCRIPTION The Engine and ECT ECU uses the signals from the throttle position sensor, air–flow meter and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the Engine and ECT ECU compares the engagement condition of the lock–up clutch with the lock–up schedule in the Engine and ECT ECU memory to detect mechanical trouble of the DSL solenoid valve, valve body and torque converter.
Page 227 DI–96 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check valve body (See page AX–8). Repair or replace the valve body. Replace the torque converter (See page AX–38). AVENSIS/CORONA SUP (RM781E)
Page 228 DI–97 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RV–03 P0773 Shift Solenoid E Electrical Malfunction (DSL Solenoid Valve) CIRCUIT DESCRIPTION The DSL solenoid valve is turned ON and OFF by signals from the Engine and ECT ECU to control the hy- draulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. DTC No.
Page 229 DI–98 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check harness and connector between Engine and ECT ECU and automatic transaxle solenoid connector. PREPARATION: Disconnect the solenoid connector from the transaxle. Disconnect the connector from the Engine and ECT ECU. CHECK: Measure the harness and connector between terminal DSL of Engine and ECT ECU and terminal DSL of solenoid connector.
Page 230 DI–99 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check shift solenoid valve DSL. Electrical Check: PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the DSL solenoid valve connector. Remove the DSL solenoid valve. (–) CHECK: Measure resistance between terminal DSL of shift sole- noid valve and solenoid body.
Page 231 DI–100 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI80H–01 P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock–up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signals to Engine and ECT ECU. Then the Engine and ECT ECU cancels operation of the lock–up clutch while braking is in progress.
Page 232 DI–101 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Lift Back (LHD): Engine and Stop Light ECT ECU Center J/B Instrument Panel J/B Instrument Panel J/B Switch STOP G–W G–W W–R G–W G–W G–W Block B–G G–W G–W High Mounted G–W MAIN Stop Stop Stop Light Light...
Page 233 DI–102 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Wagon: Engine and Stop Light ECT ECU Instrument Panel J/B Center J/B Switch STOP W–R * G–W G–W J16 * G–W G–W J34 * Block J17 * J35 * B–G High G–W G–W G–W Mounted MAIN Stop...
Page 234 DI–103 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE HINT: Read freeze frame data using hand–held tester. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was run- ning or stopped, the engine warmed up or not, the air–fuel ratio lean or rich, etc.
Page 235 DI–104 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check harness and connector between Engine and ECT ECU and stop light switch (See page IN–20). Repair or replace harness or connector. Check and replace Engine and ECT ECU (See page IN–20). AVENSIS/CORONA SUP (RM781E)
Page 236 DI–105 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RW–03 P1725 NT Revolution Sensor Circuit Malfunction (Input Turbine Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT) and the counter gear speed sensor signal (NC), the Engine and ECT ECU detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting.
Page 237 DI–106 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE – Check resistance between terminals NT and NT of Engine and ECT ECU. PREPARATION: Disconnect the connector from Engine and ECT ECU. CHECK: – Check resistance between terminals NT and NT of Engine and ECT ECU.
Page 238 DI–107 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RX–03 P1730 NC Revolution Sensor Circuit Malfunction (Counter Gear Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC) and the input turbine speed sensor signal (NT), the Engine and ECT ECU detects the shift timing of the gears and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shifting.
Page 239 DI–108 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE – Check resistance between terminals NC and NC of Engine and ECT ECU. PREPARATION: Disconnect the connector from Engine and ECT ECU. CHECK: – Check resistance between terminals NC and NC of Engine and ECT ECU.
Page 240 DI–109 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6RZ–03 P1760 Linear Solenoid for Line Pressure Control Circuit Malfunction (SLT Solenoid Valve) CIRCUIT DESCRIPTION The throttle pressure that is applied to the primary regulator valve (which modulates line pressure) causes the solenoid Line Pressure Con- valve SLT, under electronic control, to precisely and minutely trol Pressure modulate and generate line pressure according to the accelera-...
Page 241 DI–110 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Engine and ECT ECU Automatic Transaxle Solenoid Valve – L–W – D07928 AVENSIS/CORONA SUP (RM781E)
Page 242 DI–111 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check SLT solenoid valve. PREPARATION: Jack up the vehicle. Remove the oil pan. Disconnect the solenoid connector. Check Solenoid Resistance: CHECK: Measure resistance between terminals 1 and 2 of solenoid con- nector. Resistance: 5.0 –...
Page 243 DI–112 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI4ZS–05 P1780 Neutral Start Switch Malfunction CIRCUIT DESCRIPTION The neutral start switch detects the shift lever position and sends signals to the Engine and ECT ECU. The Engine and ECT ECU receives signals (NSW, R, D 2 and L) from the neutral start switch. DTC No.
Page 244 DI–113 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) WIRING DIAGRAM Engine and ECT ECU Neutral Start Switch B–Y Y–G R–L Center J/B R–B R–B Center J/B B–W B–W 20 3E W–B B–W Center J/B Instrument Panel J/B Ignition Switch GAUGE R–L B–Y IG1 AM1 Instrument Panel J/B Instrument Panel J/B...
Page 245 DI–114 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Read PNP, REVERSE, 2ND DRIVE and LOW signals. When using hand–held tester: PREPARATION: Remove the DLC3 cover. Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON.
Page 246 DI–115 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check neutral start switch. PREPARATION: Jack up the vehicle. Remove the neutral start switch. CHECK: Check continuity between each terminal shown below when the shift lever is moved to each position. Shift range Terminal No. to continuity –...
Page 247 DI–116 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI6SY–03 O/D Main Switch & O/D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the Engine and ECT ECU prohibits shifting overdrive.
Page 248 DI–117 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE O/D OFF indicator light does not light up Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between terminals 5 and 6 of O/D main switch connector. O/D main switch Resistance ∞...
Page 249 DI–118 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check OVERDRIVE CUT SW2 signal. When using hand–held tester: PREPARATION: Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON. CHECK: Read the OVERDRIVE CUT SW2 signal on the hand–held tes- ter.
Page 250 DI–119 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check harness and connector between O/D OFF indicator light and Engine and ECT ECU (See page IN–20). PREPARATION: Disconnect the connector of Engine and ECT ECU and the connector of the combination meter. CHECK: Measure the continuity between the connector of Engine and ECT ECU and the connector of the combina- tion meter.
Page 251 DI–120 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) O/D OFF indicator light remains ON Check O/D main switch. PREPARATION: Disconnect the O/D main switch connector. CHECK: Check continuity between terminals 1 and 2 of O/D main switch connector. O/D main switch Resistance ∞...
Page 252 DI–121 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI336–04 Pattern Select Switch Circuit CIRCUIT DESCRIPTION The Engine & ECT ECU memory contains the shift programs for the NORMAL, POWER and SNOW (w/ SNOW mode) patterns, 2 range, L range and the lock–up patterns. By following the programs corresponding to the signals from the pattern select switch, the neutral start switch and other various sensors, the Engine &...
Page 253 DI–122 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check PATTERN SEL SW signal. When using hand–held tester: PREPARATION: Remove the DLC3 cover. Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON. CHECK: Read the PATTERN SEL SW signal on the hand–held tester.
Page 254 DI–123 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check pattern select switch PREPARATION: Disconnect the pattern select switch connector. CHECK: Check continuity between terminals 2 and 3 (PWR, NORM), 3 and 5 (SNOW) of pattern select switch connector when the se- lect switch is set to PWR, NORM or SNOW position. Switch position Tester connection Specified condition...
Page 255 DI–124 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) DI703–03 Kick–down Switch Circuit (LHD) CIRCUIT DESCRIPTION The kick–down switch is turned ON when the accelerator pedal is depressed beyond the full throttle opening and sends signals to Engine and ECT ECU. When the kick–down switch is turned ON, the Engine and ECT ECU controls gear shifting according to the programmed shift diagrams.
Page 256 DI–125 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) INSPECTION PROCEDURE Check KICK DOWN SW signal. When using hand–held tester: PREPARATION: Remove the DLC3 cover. Connect a hand–held tester to the DLC3. Turn the ignition switch ON and hand–held tester main switch ON. CHECK: Read the KICK DOWN SW signal on the hand–held tester.
Page 257 DI–126 DIAGNOSTICS – AUTOMATIC TRANSAXLE (U240E) Check kick–down switch. PREPARATION: Disconnect the kick–down switch connector. CHECK: Check continuity at each terminal of kick–down switch connec- tor. Kick–down Switch Specified continuity Continuity D07967 No continuity Replace kick–down switch. Check harness and connector between Engine and ECT ECU and kick–down switch, kick–down switch and body ground (See page IN–30).
Page 258: Anti-Lock Brake System With Electronic Brake Force Distribution (Ebd
DI–127 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YR–01 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion.
Page 259: Customer Problem Analysis Check
DI–128 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YS–01 CUSTOMER PROBLEM ANALYSIS CHECK ABS Check Sheet Inspector’s Name Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Odometer Reading miles Brought In Date Problem First Occurred Frequency Problem Occurs Continuously Intermittently (...
Page 260: Pre-Check
DI–129 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YT–01 PRE–CHECK DIAGNOSIS SYSTEM Release the parking brake lever. Check the indicator. When the ignition switch is turned ON, check that the ABS warning light and brake warning light goes on for 3 se- conds.
Page 261 DI–130 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Clear the DTC. Using SST, connect terminals Tc and CG of DLC3. 09843 – 18040 Turn the ignition switch ON. Clear the DTC stored in ECU by depressing the brake pedal 8 or more times within 3 seconds.
Page 262 DI–131 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) (11) Read the number of blinks of the ABS warning light. HINT: See the list of DTC shown below. If every sensor is normal, a normal code is output (A cycle of 0.25 secs.
Page 263: Diagnostic Trouble Code Chart
DI–132 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YU–01 DIAGNOSTIC TROUBLE CODE CHART HINT: Using SST 09843 –18040, connect the terminals Tc and CG. If a malfunction code is displayed during the DTC check, check the circuit listed for that code. For de- tails of each code, turn to the page referred to under the ”See page”...
Page 264: Parts Location
DI–133 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YV–01 PARTS LOCATION ABS Warning Light Brake Warning Light Rear Speed Senser ABS Actuator (w/ ECU, Relay) Front Speed Sensor Rear Speed Senser Rotor Front Speed Sensor Rotor DLC3 F04286 AVENSIS/CORONA SUP (RM781E)
Page 265: Terminals Of Ecu
DI–134 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YW–01 TERMINALS OF ECU F10161 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) +B (A6 – 17, 18) – GND (A6 – B ↔ W–B Constant 10 – 14 16, 19) IG1(A6 –...
Page 266: Problem Symptoms Table
DI–135 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YX–01 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Symptoms Inspection Circuit See page...
Page 267: Circuit Inspection
DI–136 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YY–01 CIRCUIT INSPECTION ABS Solenoid Valve Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on.
Page 268 DI–137 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator connector. PREPARATION: LOCK LOCK LOCK Disconnect the ABS actuator connector. CHECK: 18 17 Measure the voltage between terminals A6 –...
Page 269 DI–138 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7YZ–01 Pump Motor Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor. DTC No.
Page 270 DI–139 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check voltage between terminals A6 – 17, 18 and A6 – 16, 19 of ABS actuator connector. PREPARATION: LOCK LOCK LOCK Disconnect the ABS actuator connector. CHECK: Measure the voltage between terminals A6 –...
Page 271 DI–140 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z0–01 21, 22, 23, 24 ABS Solenoid Valve Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force.
Page 272 DI–141 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check the DTC once more. PREPARATION: Clear the DTC (See page DI–129). Turn the ignition switch OFF. CHECK: Turn the ignition switch ON, and check if the same DTC is stored in the memory. No problem.
Page 273 DI–142 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z1–01 Speed Sensor Circuit 31, 32, 33, 34, 35, 36, 38, 39 CIRCUIT DESCRIPTION The speed sensor detects wheel speed and sends the ap- propriate signals to the ECU. These signals are used to control Speed Sensor the ABS system.
Page 274 DI–143 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) WIRING DIAGRAM ABS ECU with Actuator Left Front Speed Sensor L–W FL– Right Front W (* Speed Sensor (Shielded) (Shielded) W–R (* FR– B (* R (* W–B Left Rear Speed Sensor (Shielded)
Page 275 DI–144 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check speed sensor. Front PREPARATION: Remove the front fender liner. Disconnect the speed sensor connector. CHECK: Measure resistance between terminals 1 and 2 of speed sensor connector.
Page 276 DI–145 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open and short circuit in harness and connector between each speed sensor and ECU (See page IN–30). Repair or replace harness or connector. Check speed sensor installation. CHECK: Check the speed sensor installation.
Page 277 DI–146 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check sensor rotor and sensor tip. Front PREPARATION: Remove the front drive shaft (See page SA–3). CHECK: Check the sensor rotor serrations. No scratches or missing teeth or foreign objects. PREPARATION: Remove the front speed sensor (See Pub.
Page 278 DI–147 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z2–01 Speed Sensor Rotor Faulty CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Detection of any of conditions from 1. through 3.: 1. Occurrence of differential to some degree in the wheel speed between the front and rear wheels of either left or right side of the vehicle and the front left and right wheels.
Page 279 DI–148 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open or short circuit in harness and connector between speed sensor and ECU (See page IN–30). Repair or replace harness and connector. Check and replace ABS ECU. AVENSIS/CORONA SUP (RM781E)
Page 280 DI–149 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z3–01 Power Source Circuit CIRCUIT DESCRIPTION This circuit is the power source for the ECU, hence the actuators. DTC No. DTC Detecting Condition Trouble Area When the vehicle speed is at aprox. 6 km/h (4 mph), low S Battery battery voltage is less than 9.4 V at the time of non–opera- S IC regulator...
Page 281 DI–150 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check battery voltage. Voltage: 10 – 14 V Check and replace fuses. Check and repair the charging system. Check voltage between terminals IG1 and GND of ABS actuator connector. PREPARATION: Disconnect ABS actuator connector.
Page 282 DI–151 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check continuity between terminals GND of ABS actuator connector and body ground. CHECK: LOCK LOCK LOCK LOCK Measure resistance between terminals GND of ABS actuator harness side connector and body ground. Resistance: 1 Ω...
Page 283 DI–152 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check ECU–IG fuse. PREPARATION: Instrument Panel J/B Remove ECU–IG fuse from instrument panel J/B. CHECK: Check continuity of ECU–IG fuse. ECU–IG Continuity F12740 Check for short circuit in all the harness and components connected to ECU–IG fuse (See at- tached wiring diagram.
Page 284 DI–153 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z4–01 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area S Stop light switch Stop light switch circuit is open circuit, and stop light switch S Stop light switch circuit voltage is in the level between 65 % or more and less S ECU...
Page 285 DI–154 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Lift Back (LHD): ABS ECU with Stop Light Actuator Instrument Panel J/B Center J/B Switch STOP 10A W–R G–W G–W 140A * 120A * Fusible 100A * Link G–W G–W G–W...
Page 286 DI–155 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Wagon: ABS ECU with Actuator Stop Light Instrument Panel J/B Switch STOP 10A G–W G–W W–R * 140A * J16 * G–W G–W Fusible 120A * J34 * Link 100A * Block...
Page 287 DI–156 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check voltage between terminal STP of ABS actuator and body ground. PREPARATION: Disconnect ABS actuator connector. (–) CHECK: Measure voltage between terminal STP of ABS actuator har- ness side connector and body ground when brake pedal is de- pressed.
Page 288 DI–157 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z5–01 ABS ECU Malfunction CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area S Battery ABS ECU continuously detected the inproper operation of S ECU ABS. INSPECTION PROCEDURE Is DTC output? Check DTC on page DI–129.
Page 289 DI–158 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check voltage between terminals IG1 and GND of ABS actuator connector. PREPARATION: Disconnect ABS actuator connector. CHECK: Turn the ignition switch ON. Measure voltage between terminals IG1 and GND of ABS actuator harness side connector.
Page 290 DI–159 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z6–01 ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a DTC in memory. Connecting terminals Tc and CG of the DLC3 makes the ABS warning light blink and output the DTC.
Page 291 DI–160 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Troubleshoot in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step 1 ABS warning light remains ON Go to step 2 Check ABS warning light.
Page 292 DI–161 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z7–01 BRAKE Warning Light Circuit CIRCUIT DESCRIPTION The BRAKE warning light lights up when the brake fluid is insufficient, parking brake is applied or the EBD is defective. WIRING DIAGRAM ABS Actuator with ECU...
Page 293 DI–162 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) INSPECTION PROCEDURE Check parking brake switch circuit (See Pub. No. RM599E on page BE–45). Repair or replace parking brake switch circuit. Check brake fluid level warning switch circuit (See Pub. No. RM599E on page BE–45).
Page 294 DI–163 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open or short circuit in harness and connector (See page IN–30). Repair or replace harness or connector. Check and replace ABS ECU. AVENSIS/CORONA SUP (RM781E)
Page 295 DI–164 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z8–01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and CG of the DLC3 causes the ECU to display the DTC by flashing the ABS warning light. WIRING DIAGRAM ABS ECU with Actuator...
Page 296 DI–165 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open and short circuit in harness and connector between ABS ECU and DLC3, DLC3 and body ground (See page IN–30). Repair or replace harness or connector. Check and replace ABS ECU.
Page 297 DI–166 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7Z9–01 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and CG of the DLC3 on the lower finish panel starts the check. WIRING DIAGRAM ABS ECU with Actuator...
Page 298 DI–167 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) Check for open and short circuit in harness and connector between ABS ECU and DLC3 and body ground (See page IN–30). Repair or replace harness or connector. Check and replace ABS ECU. AVENSIS/CORONA SUP (RM781E)
Page 299 DI–168 DIAGNOSTICS – ANTI–LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) DI7ZA–01 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F04266 AVENSIS/CORONA SUP (RM781E)
Page 300: Abs With Ebd & Ba & Trc & Vsc System
DI–169 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZB–01 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion.
Page 301 DI–170 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZC–01 CUSTOMER PROBLEM ANALYSIS CHECK ABS & BA & TRC & VSC Check Sheet Inspector’s Name Registration No. Registration Data Customer’s Name Frame No. Date Vehicle Odometer Reading miles Brought In Date Problem First Occurred...
Page 302 DI–171 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZD–01 PRE–CHECK DIAGNOSIS SYSTEM Check the warning lights. Release the parking brake lever. When the ignition switch is turned ON, check that the ABS warning light, VSC warning light, VSC OFF indicator light, BRAKE warning light and SLIP indi- cator light goes on for approx.
Page 303 DI–172 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM As an example, the blinking patterns for normal code and code 31 and 32 are shown on the left. Normal Code Codes are explained in the code table on page 2 secs.
Page 304 DI–173 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM In case of using hand–held tester: Hand–held Clear the DTC. Tester Hook up the hand–held tester to the DLC3. Turn the ignition switch ON. Operate the hand–held tester to erase the codes. (See hand–held tester operator’s manual.) DLC3 D01600...
Page 305 DI–174 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM After doing the check, disconnect the SST from ter- minals Ts and CG, Tc and CG of DLC3, and turn the ignition switch OFF. 09843–18040 In case of using hand–held tester: Hand–held Check the sensor signal.
Page 306 DI–175 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM STEERING ANGLE SENSOR ZERO POINT CALIBRA- TION NOTICE: When replacing the steering angle sensor with column as- sembly or ABS & BA & TRC & VSC ECU, Engine and ECT ECU (A/T), Engine ECU (M/T) or when adjusting the front wheel alignment or steering wheel center point in accor- dance with the removing and installing or replacing the...
Page 307: Diagnostic Trouble Code Chart
DI–176 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZE–01 DIAGNOSTIC TROUBLE CODE CHART NOTICE: When removing the part, turn the ignition switch OFF. When replacing the steering angle sensor or ECU, make sure to perform steering angle sensor zero point calibration.
Page 308 DI–177 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM C1300 / 62 Malfunction in ABS & BA & TRC & VSC ECU ABS & BA & TRC & VSC ECU (DI–220) S Charging system Always ON Malfunction in ABS &...
Page 309: Parts Location
DI–178 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZF–01 PARTS LOCATION Combination Meter DABS Warning Light DVSC Warning Light DBRAKE Warning Light DVSC OFF Indicator Light DSLIP Indicator Light Rear Speed Senser Yaw Rate Sensor (Including Deceleration Sensor) Steering Angle Sensor Front Speed Sensor...
Page 310: Terminals Of Ecu
DI–179 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZG–01 TERMINALS OF ECU ABS & BA & TRC & VSC ECU: F12741 Symbols (Terminals No.) Wiring Color Condition STD Voltage (V) IG switch ON, VSC OFF indicator light ON Below 2.0 O ↔...
Page 311 DI–180 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM IG switch ON, ABS warning light ON 10 – 14 P L ↔ W B P–L ↔ W–B WA (A29 35) GND (A29 6 10) WA (A29 – 35) – GND (A29 – 6, 10) IG switch ON, ABS warning light OFF Below 2.0 L ↔...
Page 312 DI–181 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZH–01 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing ABS &...
Page 313: Circuit Inspection
DI–182 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZI–01 CIRCUIT INSPECTION Speed Sensor Circuit C0200 / 31 – C1331 / 36 Speed Sensor Circuit C1332 / 38, C1333 / 39 CIRCUIT DESCRIPTION The speed sensor detects a wheel speed and sends the ap- propriate signals to the ECU.
Page 314 DI–183 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC & VSC ECU Left Front Speed Sensor L–W FL– (Shielded) (RHD) W–R (LHD) W (RHD) Right Front Speed Sensor R (LHD) B (RHD) FR–...
Page 315 DI–184 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check speed sensor. Front: PREPARATION: Remove the front fender liner. Disconnect the speed sensor connector. CHECK: Measure the resistance between terminals 1 and 2 of speed sensor connector.
Page 316 DI–185 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between each speed sensor and ABS & BA & TRC & VSC ECU (See page IN–30). Repair or replace harness or connector. Check speed sensor installation.
Page 317 DI–186 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check speed sensor and sensor rotor serrations. REFERENCE: INSPECTION USING OSCILLOSCOPE Normal Signal Waveform PREPARATION: Disconnect the connector from the ABS & BA & TRC & VSC ECU. Connect the oscilloscope to the terminals FR+, FL+, RR+ or RL+ and GND of the ECU harness side connector.
Page 318 DI–187 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Rear: PREPARATION: Remove the axle hub ( See Pub. No. RM599E on page SA–10). CHECK: Check the sensor rotor serrations. No scratches, missing teeth or foreign objects. PREPARATION: Remove the rear speed sensor (See Pub.
Page 319 DI–188 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZJ–01 Brake Actuator Solenoid Circuit C0226 / 21 – C1228 / 28 CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force.
Page 320 DI–189 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZK–01 C0273 / 13 ABS Motor Relay Circuit CIRCUIT DESCRIPTION The ABS motor relay supplies power to the ABS pump motor. When the ABS is activated, the ECU switches the ABS motor relay ON and operates the ABS pump motor.
Page 321 DI–190 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZL–01 C0278 / 11 ABS Solenoid Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on.
Page 322 DI–191 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZM–01 C0365 / 43 Deceleration Sensor Circuit CIRCUIT DESCRIPTION Deceleration sensor is combined with yaw rate sensor. DTC No. DTC Detecting Condition Trouble Area Detection of any of conditions from 1. through 2.: S Deceleration sensor 1.
Page 323 DI–192 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC Deceleration Sensor & VSC ECU LG–R UBAT YIGA BR–W YGND (Shielded) (Shielded) (LHD) CANH CANL (Shielded) (LHD) W–B Center J/B Center J/B W–B W–B...
Page 324 DI–193 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 2 in case of not using the hand–held tester. Check output value of the deceleration sensor.
Page 325 DI–194 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZN–01 C0371 / 55 Yaw Rate Sensor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Detection of any of conditions from 1. through 4.: 1. The voltage of sensor signal is out of range. S Yaw rate sensor 2.
Page 326 DI–195 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC Yaw Rate Sensor & VSC ECU LG–R UBAT YIGA BR–W YGND (Shielded) (Shielded) (LHD) CANH CANL (Shielded) (LHD) W–B Center J/B Center J/B W–B W–B...
Page 327 DI–196 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 2 in case of not using the hand–held tester. Check output value of the yaw rate sensor.
Page 328 DI–197 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZO–01 C1202 / 44 NE Signal Circuit CIRCUIT DESCRIPTION The ABS & BA & TRC & VSC ECU receives engine revolution speed signals (NE signals) from the Engine and ECT ECU (A/T) or Engine ECU (M/T).
Page 329 DI–198 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check for open and short circuit in harness and connector between terminal NEO of ABS & BA & TRC & VSC ECU and terminal NEO of Engine and ECT ECU (A/T) or Engine ECU (M/T) (See page IN–30).
Page 330 DI–199 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check and replace ABS & BA & TRC & VSC ECU with actuator assembly or Engine and ECT ECU (A/T) or Engine ECU (M/T). If the same codes is still output after the DTC is deleted, check the contact condition of each con- nection.
Page 331 DI–200 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZP–01 C1203 / 59 EFI Communication Circuit Malfunction CIRCUIT DESCRIPTION The circuit is used to send TRAC & VSC control information from the ABS & BA & TRC & VSC ECU to the Engine and ECT ECU (A/T) or Engine ECU (M/T) (TRC+, TRC–), and engine control information from the Engine and ECT ECU (A/T) or Engine ECU (M/T) to the ABS &...
Page 332 DI–201 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check for open and short circuit in harness and connector between each of ter- minals ENG+, ENG–, TRC+ and TRC– of ABS & BA & TRC & VSC ECU and Engine ECU (M/T) or Engine and ECT ECU (A/T) (See page IN–30).
Page 333 DI–202 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZQ–01 C1208 / 54 Steering Angle Sensor Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Detection of any of conditions 1. through 7: 1. When the condition that ECU terminal IG1 voltage is 9.8 V or more, and does not receive data from steering angle sensor continues.
Page 334 DI–203 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC Steering Sensor & VSC ECU LG–R YIGA BR–W YGND (Shielded) HIGH (Shielded) (RHD) W–B Center J/B Center J/B W–B W–B Instrument Panel J/B W–B : IH (LHD)
Page 335 DI–204 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 2 in case of not using the hand–held tester. Check output value of the steering angle sensor.
Page 336 DI–205 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Calibrate the steering angle sensor (See page DI–171). Replace steering angle sensor with colum As- sembly (See page SR–6). Replace the ECU and check whether or not the trouble occurs again. Replace steering angle sensor with colum As- sembly (See page SR–6).
Page 337 DI–206 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZR–01 C1237 / 37 Wrong Number of Teeth at 1 of 4 Wheels CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Detection of any of conditions from 1. through 4.: 1.
Page 338 DI–207 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between front speed sensor, rear speed sensor and ABS & BA & TRC & VSC ECU (See page IN–30).
Page 339 DI–208 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZS–01 C1241 / 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the brake actuators. DTC No. DTC Detecting Condition Trouble Area S Battery At a vehicle speed of 6 km/h (4 mph) or more, the condition...
Page 340 DI–209 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC & VSC ECU Center J/B Instrument Panel J/B ECU–IG B–R B–R A29 IG1 B–Y Instrument Panel J/B Ignition Switch W (RHD) W (LHD) F17 1 F17 2...
Page 341 DI–210 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check ECU–IG fuse. PREPARATION: Instrument Panel J/B Remove the ECU–IG fuse from the instrument panel J/B. CHECK: Check continuity of the ECU–IG fuse. Continuity ECU–IG F12740 Check for short circuit in all the harness and components connected to ECU–IG fuse (See at-...
Page 342 DI–211 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check voltage between terminals IG1 (14) and GND (6, 10) of ABS & BA & TRC & VSC ECU. PREPARATION: Disconnect the connector from the ABS & BA & TRC & VSC ECU.
Page 343 DI–212 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZT–01 Master Cylinder Pressure Sensor Circuit C1246 / 53 CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area When any of the following 1. through 3. is detected: 1.
Page 344 DI–213 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1, in case of using the hand–held tester and start from step 2, in case of not using the hand–held tester. Check the stop light FUSE and stop light bulb.
Page 345 DI–214 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check whether or not the ECU terminal STP input voltage is changed when the stop light switch is turned on and off. Check the stop light switch circuit (See Pub. No. RM599E on page BE–45).
Page 346 DI–215 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZU–01 C1249 / 58 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area S Stop light switch After the ignition switch is turned ON, the condition that the S Stop light switch circuit C1249 / 58 STP terminal voltage of ECU is 55 % to 75 % of supplied...
Page 347 DI–216 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Lift Back (LHD): ABS & BA & TRC & Stop Light VSC ECU Instrument Panel J/B Center J/B Switch STOP 10A W–R G–W G–W Fusible Link G–W G–W G–W Block...
Page 348 DI–217 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Wagon: ABS &BA & TRC & VSC ECU Stop Light Instrument Panel J/B Switch STOP 10A G–W G–W W–R * J16 * G–W G–W Fusible J34 * Link 120A Block...
Page 349 DI–218 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check voltage between terminal STP (37) of ABS & BA & TRC & VSC ECU and body ground. PREPARATION: Disconnect the connector from the ABS & BA & TRC & VSC ECU.
Page 350 DI–219 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZV–01 C1288 / 88 ECU Version Miss Match CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area When any of the following 1, through 2, is detecte: S ABS &...
Page 351 DI–220 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZW–02 ABS & BA & TRC & VSC ECU Malfunction C1300 / 62 CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area ABS & BA & TRC & VSC ECU internal malfunction is de- C1300 / 62 ABS &...
Page 352 DI–221 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZX–01 Brake Actuator Pump Motor Failure C1350 / 51 CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area When any of the following 1. through 3. is detected. 1.
Page 353 DI–222 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZY–01 C1352 / 42 CAN Communication System Malfunc- tion CIRCUIT DESCRIPTION The circuit is used to send TRC & VSC control information from yaw rate sensor and steering angle sensor information to ABS &...
Page 354 DI–223 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM Steering Sensor (Shielded) LG–R BR–W HIGH ABS & BA & TRC & VSC ECU Yaw Rate Sensor LG–R LG–R YIGA UBAT BR–W BR–W YGND (Shielded) (Shielded) (LHD) CANH...
Page 355 DI–224 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check for open and short circuit in harness and connector between each of ter- minals CANLOW and CANHIGH of steering angle sensor, CANL and CANH of yaw rate sensor and ABS &...
Page 356 DI–225 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI7ZZ–01 Always ON Malfunction in ECU ABS Warning Light Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Either of the following 1., 2. or 3. is detected: S Charging system 1.
Page 357 DI–226 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check that the ECU connectors are securely connected to the ECU. Connect the connector to the ECU. Is DTC output? Check DTC on page DI–171. Repair circuit indicated by the output code .
Page 358 DI–227 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check voltage between terminals IG1 (14) and GND (6,10)or ABS & BA & TRC & VSC ECU. PREPARATION: Disconnect the connector from the ABS & BA & TRC & VSC ECU.
Page 359 DI–228 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI800–01 Always ON Malfunction in ECU VSC Warning Light Circuit CIRCUIT DESCRIPTION DTC No. DTC Detecting Condition Trouble Area Either of the following 1. or 2. is detected: S Charging system Always ON 1.
Page 360 DI–229 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Does both VSC warning light and VSC OFF indicator light go on? Go to step 4. Is DTC output? Check DTC on page DI–171. Repair circuit indicated by the output code . Check for open or short circuit in harness and connector between combination mater and ABS &...
Page 361 DI–230 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check the steering angle sensor calibration. Calibrate the steering angle sensor (See page DI–171). Check and replace ABS & BA & TRC & VSC ECU with actuator assembly. AVENSIS/CORONA SUP (RM781E)
Page 362 DI–231 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI801–01 ABS Warning Light Circuit (Does Not Light Up) WIRING DIAGRAM ABS & BA & TRC & VSC ECU Combination Meter Center J/B P–L R–L R–L R–L Instrument Panel J/B Ignition SW GAUGE 10A...
Page 363 DI–232 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using a hand–held tester and start from step 2 in case of not using the hand–held tester. Check operation of the ABS warning light.
Page 364 DI–233 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI802–01 VSC Warning Light Circuit (Does Not Light Up) CIRCUIT DESCRIPTION If the ECU stores DTC to be necessary to shut down VSC operation, the VSC warning light lights on the combination meter.
Page 365 DI–234 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 2 in case of not using the hand–held tester. Check operation of the VSC warning light.
Page 366 DI–235 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check VSC warning light. See the combination meter troubleshooting (See Pub. No. RM599E on page BE–57). Repair or replace bulb or combination meter. Check and replace ABS & BA & TRC & VSC ECU with actuator aseembly.
Page 367 DI–236 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI803–01 BRAKE Warning Light Circuit CIRCUIT DESCRIPTION The BRAKE warning light lights up when the brake fluid is insufficient, when the parking brake is applied or when the EBD is defective. AVENSIS/CORONA SUP (RM781E)
Page 368 DI–237 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & TRC & VSC ECU Combination Meter Center J/B R–W R–L EBDW BRAKE R–L Resistor B–R R–W R–W R–W R–L (LHD) (RHD) R–W Instrument Panel J/B Center J/B...
Page 369 DI–238 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE Check parking brake switch circuit (See Pub. No. RM599E on page BE–57). Repair or replace parking brake switch circuit. Check brake fluid level warning switch circuit (See Pub. No. RM599E on page BE–57).
Page 370 DI–239 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open or short circuit in harness and connector between combination meter and ABS & BA & TRC & VSC ECU (See page IN–30). Repair or replace harness or connector. Check and replace ABS &...
Page 371 DI–240 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI804–01 SLIP Indicator Light Circuit CIRCUIT DESCRIPTION The SLIP indicator light blinks during TRC & VSC operation. WIRING DIAGRAM ABS & BA & TRC & VSC ECU Combination Meter Center J/B R–L...
Page 372 DI–241 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1, in case of using the hand–held tester and start from step 2, in case of not using the hand–held tester. Check operation of the SLIP indicator light.
Page 373 DI–242 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA TRC & VSC ECU and SLIP indicator light (See page IN–30). Repair or replace harness or connector. Check and replace ABS &...
Page 374 DI–243 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI805–01 VSC OFF Indicator Light, VSC OFF Switch Circuit CIRCUIT DESCRIPTION This is the TRC & VSC control main switch. When the VSC OFF switch is pressed, TRC & VSC control is deactivated and the VSC OFF indicator light lights up.
Page 375 DI–244 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM WIRING DIAGRAM ABS & BA & Combination TRC & VSC ECU Meter Center J/B R–L R–L R–L G–W Instrument Panel J/B (LHD) GAUGE 10A VSC Off SW B–Y G–R G–R...
Page 376 DI–245 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 2 in case of not using the hand–held tester. Check operation of the VSC OFF indicator light.
Page 377 DI–246 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between terminal CSW of ABS & BA & TRC & VSC ECU and VSC OFF switch and body ground (See page IN–30).
Page 378 DI–247 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI806–01 VSC Buzzer Circuit CIRCUIT DESCRIPTION The VSC buzzer sounds during VSC operation. WIRING DIAGRAM ABS & BA & TRC & VSC ECU VSC Warning Center J/B Buzzer R–L R–L...
Page 379 DI–248 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM INSPECTION PROCEDURE HINT: Start the inspection from step 1 in case of using the hand–held tester and start from step 3 in case of not using the hand–held tester. Check operation of the VSC buzzer.
Page 380 DI–249 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check VSC buzzer. PREPARATION: Disconnect the VSC buzzer connector. CHECK: (–) Apply battery voltage to the terminals 1 and 2 of VSC buzzer connector, and check that the VSC buzzer sounds. F02192 Replace VSC buzzer.
Page 381 DI–250 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI807–01 Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminals Tc and CG of the DLC3 causes the ECU to display DTC by blinking the ABS warning light, VSC warning light and BRAKE warning light. WIRING DIAGRAM ABS &...
Page 382 DI–251 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA & TRC & VSC ECU and DLC3, DLC3 and body ground (See page IN–30). Repair or replace harness or connector.
Page 383 DI–252 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI808–01 Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormality in the speed sensor signal which cannot be detected with the DTC check. Connecting terminals Ts and CG of the DLC3 starts the check. WIRING DIAGRAM ABS &...
Page 384 DI–253 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM Check for open and short circuit in harness and connector between ABS & BA & TRC & VSC ECU and DLC3, DLC3 and body ground (See page IN–30). Repair or replace harness or connector.
Page 385 DI–254 DIAGNOSTICS – ABS WITH EBD & BA & TRC & VSC SYSTEM DI809–01 Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. F04266 AVENSIS/CORONA SUP (RM781E)
Page 386 DI–255 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM ENGINE IMMOBILISER SYSTEM DI7FG–03 HOW TO PROCEED WITH TROUBLESHOOTING Troubleshooting in accordance with the procedure on the following pages. Vehicle Brought to Workshop Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations.
Page 387: Engine Immobiliser System
DI–256 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FH–01 CUSTOMER PROBLEM ANALYSIS CHECK ENGINE IMMOBLISER Check Sheet Inspector’s Name Registration No. Registration Year Customer’s Name Frame No. Date Vehicle Odometer Reading miles Brought In Date Problem First Occurred Frequency Problem Occurs Continuous Intermittent ( times a day) Immobiliser is not set.
Page 388 DI–257 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7W6–02 PRE–CHECK Hand–held Tester DIAGNOSIS SYSTEM Description Engine ECU controls the function of immobiliser on this vehicle. Data of the immobiliser or Diagnostic Trouble Code (DTC) can be read from the Data Link Connector 3 (DLC3) of the DLC3 vehicle.
Page 389 DI–258 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECT DIAGNOSIS Using hand–held tester: Check the DTC. NOTICE: Hand–held tester only: When the diagnosis system is switched from the normal mode to the check mode, it erases all DTCs and freezed frame data recorded in the normal mode. So before switch- ing the modes, always check the DTCs and freezed frame data, and note them down.
Page 390: Diagnostic Trouble Code Chart
DI–259 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FJ–02 DIAGNOSTIC TROUBLE CODE CHART DTC No. Detection Item Trouble Area (See page) S Key B2795 Unmatched Key Code S Unregistered key inserted before (DI–264) S Key S Transponder key amplifier B2796 No Communication in Immobiliser System S Wire harness (DI–265) S Engine ECU...
Page 391: Parts Location
DI–260 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FK–03 PARTS LOCATION Engine Room J/B S EFI Fuse S EFI Relay Engine ECU Transponder Key Amplifier DLC3 Ignition Switch I19380 AVENSIS/CORONA SUP (RM781E)
Page 392: Terminals Of Ecu
DI–261 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI80I–01 TERMINALS OF ECU 1AZ–FSE Engine ECU Terminals D01054 D03442 Symbols (Terminal No.) Wiring Color Condition STD Voltage (V) CODE (E13–14) – B – BR Ignition switch ON 9 – 14 E1 (E16–3) RXCK 〈E13–13) – B–O –...
Page 393 DI–262 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM 1ZZ–FE (M/T) and 3ZZ–FE Engine ECU Terminals D00032 Symbols (Terminal No.) Wiring Color Condition STD Voltage (V) CODE (E20–19) – B – BR Ignition switch ON 9 – 14 E1 (E18–14) RXCK (E20–20) – B–O –...
Page 394 DI–263 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FM–02 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See page Immobiliser is not set 1. Engine ECU IN–30 (Engine starts with key codes other than the registered key code) 1. Key 2. Wire harness IN–30 Engine does not start 3.
Page 395: Circuit Inspection
DI–264 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FN–01 CIRCUIT INSPECTION B2795 Unmatched Key Code CIRCUIT DESCRIPTION This DTC is output when an unregistered key is inserted. When this DTC is output, delete DTC and insert the key of the customer to check that DTC B2795 is output. When the key that outputs DTC B2795, register this key.
Page 396 DI–265 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FO–03 B2796 No Communication in Immobiliser system CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S Key S Transponder key amplifier B2796 No communication S Wire harness S Engine ECU WIRING DIAGRAM Transponder Key Amplifier Engine ECU CODE CODE...
Page 397 DI–266 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE Delete DTC and insert all presently available keys to check whether engine starts or not RESULT: All keys start engine. A specific key does not start engine. In this case, DTC B2796 is stored in memory. All keys do not start engine.
Page 398 DI–267 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FP–03 B2797 Communication Malfunction No. 1 CIRCUIT DESCRIPTION This code is detected when an error occurs despite of normal communication. (Example: Some noise is included in communication line.) DTC No. DTC Detection Condition Trouble Area S Wire harness S Transponder key amplifier B2797...
Page 399 DI–268 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FQ–02 B2798 Communication Malfunction No. 2 CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S Key S Transponder key amplifier B2798 Communication error S Wire harness S Engine ECU WIRING DIAGRAM Refer to DTC B2796 on page DI–265. INSPECTION PROCEDURE Check harness and connector between transponder key amplifier and engine ECU (See page IN–30).
Page 400 DI–269 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM DI7FR–03 Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the transponder key amplifier. WIRING DIAGRAM Engine Room J/B Transponder Key Amplifier EFI Relay L–Y W–B W–B B–G Center J/B From Terminal W–B W–B MREL...
Page 401 DI–270 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM INSPECTION PROCEDURE Check voltage between terminals +B and GND of transponder key amplifier con- nector. PREPARATION: Turn the ignition switch OFF. Disconnect the transponder key amplifier connector. CHECK: Measure the voltage between terminals +B and GND of the transponder key amplifier connector.
Page 402 DI–271 DIAGNOSTICS – ENGINE IMMOBILISER SYSTEM Check harness and connector between transponder key amplifier and body ground (See page IN–30). Repair or replace harness or connector. Check and repair harness and connector be- tween transponder key amplifier and battery (See page IN–30). AVENSIS/CORONA SUP (RM781E)
Page 404 CLUTCH CLUTCH PEDAL ......CL–1 CLUTCH MASTER CYLINDER ... . CL–3 CLUTCH UNIT .
Page 406 CL–1 CLUTCH – CLUTCH PEDAL CLUTCH PEDAL Push Rod Play and Freeplay Adjust Point CL015–05 INSPECTION CHECK PEDAL HEIGHT Pedal height from asphalt sheet: LHD: 1ZZ–FE Engine: 139.7 – 149.7 mm (5.500 – 5.894 in.) 3ZZ–FE Engine: Pedal Height Adjust Point 139.7 –...
Page 407 CL–2 CLUTCH – CLUTCH PEDAL CHECK CLUTCH RELEASE POINT Pull the parking brake lever and install wheel stopper. Start the engine and idle the engine. 25 mm (0.98 in) or more Without depressing the clutch pedal, slowly shift the shift Release lever into reverse position until the gears make contact.
Page 408 CL–3 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER CL016–03 COMPONENTS LHD: Lock Nut Clevis Filler Cap Boot Snap Ring Clip Reservoir Tank Push Rod Reservoir Hose 12 (120, 9) Piston Clip Spring Clip 1CD–FTV Engine LHD: w/ Damper: Inlet Union O–Ring Washer Clutch Line...
Page 409 CL–4 CLUTCH – CLUTCH MASTER CYLINDER 1CD–FTV Engine RHD: Filler Cap Float Clevis Reservoir Tank Snap Ring Clip Push Rod 12 (120, 9) Piston zGrommet Spring Slotted Spring Lock Nut Boot Washer Clutch Line 15 (155, 11) Master Cylinder z Gasket Body Clutch Accumulator For use with SST: 32 (330, 24)
Page 410 CL–5 CLUTCH – CLUTCH MASTER CYLINDER CL017–07 REMOVAL DRAW OUT FLUID WITH SYRINGE LHD: DISCONNECT RESERVOIR TANK Disconnect reservoir tank from reservoir tank bracket. D02438 LHD: LHD: DISCONNECT CLUTCH LINE Using SST, disconnect the clutch line. Use a container to catch the fluid.
Page 411 CL–6 CLUTCH – CLUTCH MASTER CYLINDER CL051–02 DISASSEMBLY LHD: REMOVE RESERVOIR TANK Yellow Mark Using a pliers, disconnect the 2 clips. Remove the reservoir tank from reservoir hose. Remove the reservoir hose from inlet union. White Mark D02444 Remove the inlet union. D02445 RHD: REMOVE RESERVOIR TANK...
Page 412 CL–7 CLUTCH – CLUTCH MASTER CYLINDER CL052–03 REASSEMBLY 1CD–FTV ENGINE RHD: INSTALL CLUTCH ACCUMULATOR Using SST, install the accumulator with a new gasket. 09922–10010 Torque: Fulcrum For use with SST: Length 32 N·m (330 kgf·cm, 24 ft·lbf) D00280 For use without SST 44 N·m (450 kgf·cm, 33 ft·lbf) HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58...
Page 413 CL–8 CLUTCH – CLUTCH MASTER CYLINDER CL01A–02 INSTALLATION Installation is in the reverse order of removal (See page CL–5). HINT: After installation, bleed the clutch system and adjust the clutch pedal. AVENSIS/CORONA SUP (RM781E)
Page 414 CL–9 CLUTCH – CLUTCH UNIT CLUTCH UNIT CL01J–04 COMPONENTS 19 (195, 14) Release Bearing Release Fork Support Clip : 37 (375, 27) : 39 (400, 29) Flywheel Clutch Disc Clutch Cover Release Fork Boot : 1ZZ–FE, 3ZZ–FE Engine : 1CD–FTV Engine N·m (kgf·cm, ft·lbf) : Specified torque D00201 AVENSIS/CORONA SUP (RM781E)
Page 415 CL–10 CLUTCH – CLUTCH UNIT CL01K–04 REMOVAL REMOVE TRANSAXLE FROM ENGINE C50, C250 M/T: See page MX–2 S54, S55 M/T: See page MX–2 E351 M/T: See page MX–2 REMOVE CLUTCH COVER AND DISC Place matchmarks on the flywheel and clutch cover. Loosen each set bolt one turn at a time until spring tension is released.
Page 416 CL–11 CLUTCH – CLUTCH UNIT CL01L–04 INSPECTION INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.012in.) If necessary, replace the clutch disc. Q01057 INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc. Maximum runout: 0.8 mm (0.031 in.) If necessary, replace the clutch disc runout.
Page 417 CL–12 CLUTCH – CLUTCH UNIT CL01M–04 INSTALLATION INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL Flywheel Side 1CD–FTV Engine: Insert SST in the clutch disc, and then insert them in the flywheel. 09301–00210 HINT: Take care not to insert clutch disc in the wrong direction. D00682 Others: Insert SST in the clutch disc, and then insert them in the...
Page 418 CL–13 CLUTCH – CLUTCH UNIT INSTALL RELEASE BEARING AND FORK TO TRANS- AXLE Install the bearing to the release fork, and then install them to the transaxle. INSTALL TRANSAXLE TO ENGINE C50, C250 M/T: See page MX–2 S54, S55 M/T: See page MX–2 E351 M/T: See page MX–2 AVENSIS/CORONA SUP (RM781E)
Page 420 MANUAL TRANSAXLE (C50, C250) TROUBLESHOOTING ....MX–1 MANUAL TRANSAXLE UNIT ....MX–2 MANUAL TRANSAXLE ASSEMBLY .
Page 422: Troubleshooting
MX–1 MANUAL TRANSAXLE (C50, C250) – TROUBLESHOOTING TROUBLESHOOTING MX002–02 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 parts. Symptom Suspect Area See page...
Page 423: Manual Transaxle Unit
MX–2 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX06E–02 COMPONENTS RH Drive Shaft Battery Snap Ring Tray Back–Up Light Switch Connector Engine Wire Speed Sensor Connector 87 (890, 64) 46 (470, 34) 39 (400, 29) Air Cleaner Starter Ground Cable 64 (650, 47)
Page 424 MX–3 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT MX0CZ–01 REMOVAL REMOVE BATTERY AND AIR CLEANER CASE AS- SEMBLY WITH AIR HOSE DISCONNECT CLUTCH RELEASE CYLINDER AND LINE Remove the set bolt of the clutch line bracket. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) Remove the 2 bolts and disconnect the clutch release cyl- inder and line.
Page 425 MX–4 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT INSTALL ENGINE SUPPORT FIXTURE D02147 REMOVE ENGINE LEFT MOUNTING BRACKET Remove the 4 bolts, nut and bracket. Torque: Bolt A: 52 N·m (530 kgf·cm, 38 ft·lbf) Nut B : 87 N·m (890 kgf·cm, 64 ft·lbf) REMOVE FRONT WHEEL Torque: 216 N·m (2,200 kgf·cm, 159 ft·lbf) RAISE VEHICLE...
Page 426 MX–5 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT REMOVE ENGINE MOUNTING CENTER MEMBER Remove the 2 bolts and front transport hook. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) D02150 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: 72 N·m (730 kgf·cm, 53 ft·lbf)
Page 427 MX–6 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine. HINT: At the time of installation, please refer to the following items. Align the input shaft with the clutch disc and install the transaxle to the engine.
Page 428 MX–7 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE UNIT MX005–04 INSTALLATION Installation is in the reverse order of removal (See page MX–3). HINT: After installation, check and inspect items as follows. Front wheel alignment (See Pub. No. RM599E on page SA–4). Do the road test.
Page 429: Manual Transaxle Assembly
MX–8 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX006–06 COMPONENTS 11 (115, 8) Hole Cover Control Cable Bracket 25 (250, 18) 29 (300, 22) Transaxle Case Receiver Transaxle Case 11 (115, 8) Magnet Oil Seal Input Shaft Front Bearing Output Shaft Cover Output Shaft Front Bearing Differential Case Assembly...
Page 430 MX–9 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY L Straight Screw Plug No.1 Shift Fork 25 (250, 18) Reverse Shift Arm Bracket Spring Seat Reverse Shift Fork Spring 16 (160, 12) Ball Snap Ring No.1 Shift Fork Shaft 25 (250, 18) 17 (175, 13) No.3 Shift Fork Shaft Thrust Washer...
Page 431 MX–10 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY 20 (200, 14) Back–Up Control Shaft Cover Light Switch 40 (410, 30) Gasket L Straight Screw Plug 39 (400, 29) 20 (200, 14) z Gasket Bearing Oil Receiver Pipe L Lock Ball Assembly 39 (400, 29) L Straight Screw Plug 13 (130, 9)
Page 432 MX–11 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY MX0D0–01 DISASSEMBLY REMOVE RELEASE FORK AND BEARING HINT: At the time of reassembly, please refer to the following item. Apply molybdenum disulphide lithium base grease. (See page CL–12) REMOVE BOLT AND SPEED SENSOR Torque: 11 N·m (115 kgf·cm, 8 ft·lbf) REMOVE BACK–UP LIGHT SWITCH Torque: 40 N·m (410 kgf·cm, 30 ft·lbf)
Page 433 MX–12 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY REMOVE CONTROL SHIFT LEVER AND DUST BOOT Remove the nut and wave washer. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D07395 Using a pin punch and hammer, drive out the lever lock pin.
Page 434 MX–13 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY REMOVE SHIFT AND SELECT LEVER SHAFT AS- SEMBLY Remove the shift and select lever shaft assembly. NOTICE: At the time of reassembly, please refer to the following item. Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely.
Page 435 MX–14 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.10–0.57 mm (0.0039–0.0024 in.) Maximum clearance: 0.57 mm (0.0224 in.) Q02519 INSPECT 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance.
Page 436 MX–15 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY Install a bolt and washer to the tip of the input shaft and using SST, remove the No.3 clutch hub. 09950–30011 NOTICE: Engine Side Select a bolt whose outer diameter is smaller than the screw hole of the input shaft so that it can be turned easily.
Page 437 MX–16 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY REMOVE PLUG, SEAT, SPRING AND BALL Using a hexagon wrench, remove the 3 plugs. Sealant: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Using a magnetic finger, remove the 3 seats, springs and balls.
Page 438 MX–17 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY REMOVE REVERSE SHIFT ARM BRACKET Remove the 2 bolts and reverse shift arm bracket. Torque: 17 N·m (175 kgf·cm, 13 ft·lbf) NOTICE: At the time of reassembly, please refer to the following items.
Page 439 MX–18 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY Remove the No. 1 gear shift head. D03038 Using a magnetic finger, remove the 2 balls from the re- verse shift fork. Remove the No. 3 gear shift fork shaft and reverse shift fork.
Page 440 MX–19 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY MX06G–02 INSPECTION INSPECT 5TH GEAR SYNCHRONIZER RING Check 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 441 MX–20 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY Using SST and a press, install a new bearing. 09950–60010 (09951–00460), 09950–70010 (09951–07150) Q07845 IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING Remove the bolt and bearing lock plate. Using SST, pull out the bearing. 09308–00010 Remove the output shaft front cover.
Page 442 MX–21 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY IF NECESSARY, REPLACE REVERSE RESTRICT PIN Using a hexagon wrench, remove the straight screw plug. Using a pin punch and hammer, drive out the slotted spring pin. Q07850 Replace the reverse restrict pin. Using a pin punch and hammer, drive in the slotted spring pin.
Page 443 MX–22 MANUAL TRANSAXLE (C50, C250) – MANUAL TRANSAXLE ASSEMBLY MX009–02 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MX–11). HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. NOTICE: When working with FIPG material, you must observe the following items. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur- faces.
Page 444: Input Shaft
MX–23 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT INPUT SHAFT MX00A–03 COMPONENTS Input Shaft 3rd Gear No.2 Hub Sleeve Shifting Key Shifting Key Spring Needle Roller Bearing Needle Roller Bearing 4th Gear Synchronizer Ring Snap Ring No.2 Clutch Hub Synchronizer Ring Snap Ring Rear Ball Bearing Q07849...
Page 445 MX–24 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT MX00B–03 DISASSEMBLY INSPECT 3RD AND 4TH GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. 3rd Gear Standard clearance: 3rd gear: 0.10–0.35 mm (0.0039–0.0138 in.) 4th Gear 4th gear: 0.10–0.55 mm (0.0039–0.0217 in.) Maximum clearance: 3rd gear: 0.35 mm (0.0138 in.) Q05793...
Page 446 MX–25 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEAR- Using SST and a press, remove the No.2 hub sleeve assembly, 3rd gear, synchronizer ring and needle roller bearings. 09950–00020 CM0064 REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND...
Page 447 MX–26 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT MX00C–03 INSPECTION INSPECT SYNCHRONIZER RING Check 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 448 MX–27 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the in- put shaft journal surface. Minimum outer diameter: Part A: 24.885 mm (0.9797 in.) Part B: 28.985 mm (1.1411 in.) Part C: 30.985 mm (1.2199 in.) Part D: 24.985 mm (0.9834 in.)
Page 449 MX–28 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT MX00D–03 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. Front Side INSTALL NO.2 CLUTCH HUB INTO NO.2 HUB SLEEVE Install the 3 springs and shifting keys to the No.2 clutch hub.
Page 450 MX–29 MANUAL TRANSAXLE (C50, C250) – INPUT SHAFT Using SST and a press, install the rear ball bearing. 09608–03071 SM0049 INSTALL SNAP RING Select a snap ring that allows the minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) 2.29 (0.0902) 2.47 (0.0972) 2.35 (0.0925)
Page 451: Output Shaft
MX–30 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT OUTPUT SHAFT MX00E–03 COMPONENTS Ball Output shaft Thrust Washer Needle Roller Bearing Synchronizer Ring 1st Gear No.1 Clutch Hub No.1 Hub Sleeve Synchronizer Ring Snap Ring Shifting Key Spring Shifting Key Spacer Needle Roller Bearing 2nd Gear Output Gear Spacer...
Page 452 MX–31 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT MX00F–03 DISASSEMBLY INSPECT 1ST AND 2ND GEARS THRUST CLEAR- ANCES Using a feeler gauge, measure each thrust clearance. 2nd Gear Standard clearance: 1st gear: 0.10–0.40 mm (0.0039–0.0157 in.) 1st Gear 2nd gear: 0.10–0.45 mm (0.0039–0.0177 in.) Maximum clearance: 1st gear: 0.40 mm (0.0157 in.) Q05794...
Page 453 MX–32 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND SPACER Shift the No.1 hub sleeve into the 1st gear. N00074 Using SST and a press, remove the 3rd driven gear. 09950–00020 Remove the 2nd gear, needle roller bearing, synchronizer ring and spacer.
Page 454 MX–33 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT MX0D1–01 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.
Page 455 MX–34 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT INSPECT GEAR SHIFT FORK AND REVERSE GEAR CLEARANCE Using a feeler gauge, measure the clearance between the re- verse gear and gear shift fork. Maximum clearance: 0.35 mm (0.014 in.) If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.
Page 456 MX–35 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT MX00H–03 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. Front Side INSTALL NO.1 CLUTCH HUB INTO NO.1 HUB SLEEVE Install the 3 springs and shifting keys to the No.1 clutch hub.
Page 457 MX–36 MANUAL TRANSAXLE (C50, C250) – OUTPUT SHAFT INSTALL SYNCHRONIZER RING, SPACER, NEEDLE ROLLER BEARING, 2ND GEAR AND 3RD DRIVEN GEAR Place the synchronizer ring on the gear and align the clutch hub grooves with the projections on the synchro- nizer ring.
Page 458: Shift And Select Lever Shaft
MX–37 MANUAL TRANSAXLE (C50, C250) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX00I–06 COMPONENTS Shift and Select Lever Shaft Snap Ring Compression Spring Select Inner Lever Shift Interlock Plate No. 2 Shift Inner Lever No. 1 Select Spring Seat No.
Page 459: Differential Case
MX–38 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX00J–03 COMPONENTS z Outer Race and Side Bearing Pinion Thrust Washer z Oil Seal Ring Gear Pinion Gear Shim Pinion Shaft 77 (790, 57) z Side Bearing and Outer Race Side Gear Shim Side Gear Thrust Washer...
Page 460 MX–39 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE MX00K–03 DISASSEMBLY REMOVE RING GEAR Place matchmarks on the ring gear and case. Matchmarks Remove the 8 bolts. Using a copper hammer, tap on the ring gear to remove it from the case. D00855 Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL...
Page 461 MX–40 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE Transmission Case Side: IF NECESSARY, REPLACE OIL SEAL AND SIDE BEARING OUTER RACE Using a screwdriver and hammer, drive out the oil seal. Using SST, pull out the outer race and shim. 09612–65014 Place the shim into the case.
Page 462 MX–41 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE Using SST and a hammer, drive in a new oil seal. 09350–32014 (09351–32130, 09351–32150) 1.9 ± 0.3 mm Drive in depth: 1.9 ± 0.3 mm (0.075 ± 0.012 in.) Coat the lip of the oil seal with MP grease. Z02714 AVENSIS/CORONA SUP (RM781E)
Page 463 MX–42 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE MX00L–03 REASSEMBLY ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will allow that the backlash is within the specification. Standard backlash: 0.05 –...
Page 464 MX–43 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE Using SST and a press, install a new side bearing. 09550–10013 (09556–10011), 09950–60010 (09951–00460), 09950–70010 (09951–07150) INSTALL RING GEAR ON DIFFERENTIAL CASE Clean the contact surface of the differential case. Heat the ring gear in boiling water. Carefully take the ring gear out of the water.
Page 465 MX–44 MANUAL TRANSAXLE (C50, C250) – DIFFERENTIAL CASE Using SST and a torque wrench, measure the preload. 09564–32011 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, remove the trans- mission case side outer race of the side bearing with SST.
Page 466: Shift Lever And Control Cable
MX–45 MANUAL TRANSAXLE (C50, C250) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX06H–02 COMPONENTS Console Box Assembly Parking Brake Cover Shift Lever Knob Front Ash Receptacle Shift Lever Assembly 12 (120, 9) Clip Air Duct 4.9 (50, 43in.·lbf) Clip Transmission Control Cable Bracket Washer...
Page 468 MANUAL TRANSAXLE (E351) TROUBLESHOOTING ....MX–1 MANUAL TRANSAXLE UNIT ....MX–2 MANUAL TRANSAXLE ASSEMBLY .
Page 470: Troubleshooting
MX–1 MANUAL TRANSAXLE (E351) – TROUBLESHOOTING TROUBLESHOOTING MX01Z–07 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 471: Manual Transaxle Unit
MX–2 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX096–03 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 472 MX–3 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT 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 473 MX–4 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT MX097–03 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 474 MX–5 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT 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 475 MX–6 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT 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 476 MX–7 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT 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 477 MX–8 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE UNIT MX05P–03 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 on page SA–4). Do the road test.
Page 478: Manual Transaxle Assembly
MX–9 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX098–03 COMPONENTS Clutch Release Assembly with Bearing Clutch Release Fork Support 17 (175, 13) Boot 17 (175, 13) Speed Sensor L Straight Screw Plug 25 (250, 18) Control Cable Bracket Transaxle Case Receiver Clutch Tube Bracket 7.4 (75, 65 in.·lbf)
Page 479 MX–10 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Arm Bracket Assembly Reverse Shift Fork No. 1 Shift Fork 24 (240, 17) L Straight Screw Plug 25 (250, 18) No. 1 Shift Fork Shaft Snap Ring 17 (175, 13) No.
Page 480 MX–11 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY Input Shaft Assembly z Output Shaft Rear Output Shaft Assembly Bearing Outer Race Reverse Idler Gear Shim Thrust Washer Reverse Idler Gear Shaft L Lock Bolt 29 (300, 22) 42 (430, 31) Rear Bearing Retainer Snap Ring Needle Roller Bearing...
Page 481 MX–12 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY MX099–03 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 SELECTING BELLCRANK ASSEMBLY Remove the 2 bolts and No.2 selecting bellcrank with the se- lecting bellcrank support.
Page 482 MX–13 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY 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. Minimum clearance: 0.10 mm (0.0039 in.) Maximum clearance: 0.65 mm (0.0256 in.) Z01304...
Page 483 MX–14 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY Using SST, remove the No.3 clutch hub with the synchro- nizer ring and 5th gear. 09950–30011 REMOVE NEEDLE ROLLER BEARING AND SPACER REMOVE REAR BEARING RETAINER Using a torx socket wrench (T45), remove the 7 torx screws and rear bearing retainer.
Page 484 MX–15 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY REMOVE TRANSMISSION CASE Remove the 17 bolts and tap the case with a plastic hammer. FIPG: Part No. 08826–00090, THREE BOND 1281 or equiva- FIPG lent Torque: 29 N·m (300 kgf·cm, 22 ft·lbf) D10267 REMOVE SHIM HINT:...
Page 485 MX–16 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY REMOVE STRAIGHT SCREW PLUG Using a hexagon wrench (6 mm), remove the 2 plugs. Sealant: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) D09368 REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD SET BOLT...
Page 486 MX–17 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY Leaning the output shaft to the differential side, remove the input shaft assembly. Lift up the differential case assembly, remove the output shaft assembly. REMOVE MAGNET FROM TRANSAXLE CASE REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB Remove the No.5 synchronizer ring with the key spring...
Page 487 MX–18 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY MX05W–03 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 488 MX–19 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY 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 489 MX–20 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY 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 490 MX–21 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY MX05X–04 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 491 MX–22 MANUAL TRANSAXLE (E351) – MANUAL TRANSAXLE ASSEMBLY 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 492: Input Shaft
MX–23 MANUAL TRANSAXLE (E351) – INPUT SHAFT INPUT SHAFT MX028–06 COMPONENTS Synchronizer Ring Spacer 4th Gear Snap Ring Needle Roller Bearing Needle Roller 3rd Gear Bearing Rear Bearing Spring Snap Ring Synchronizer Ring Input Shaft No. 2 Hub Sleeve No. 2 Clutch Hub Shifting Key z Input Shaft Front Bearing Inner Race z Non–reusable part...
Page 493 MX–24 MANUAL TRANSAXLE (E351) – INPUT SHAFT MX029–04 DISASSEMBLY MEASURE 3RD AND 4TH GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. Minimum clearance: 3rd gear and 4th gear: 0.10 mm (0.0039 in.) 3rd Gear Maximum clearance: 4th Gear 3rd gear: 0.40 mm (0.0157 in.) 4th gear: 0.60 mm (0.0236 in.)
Page 494 MX–25 MANUAL TRANSAXLE (E351) – INPUT SHAFT MX02A–04 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 495 MX–26 MANUAL TRANSAXLE (E351) – INPUT SHAFT 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: 0.69 mm (0.027 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Page 496 MX–27 MANUAL TRANSAXLE (E351) – INPUT SHAFT MX0D2–01 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. Press Install the hub sleeve to the clutch hub.
Page 497 MX–28 MANUAL TRANSAXLE (E351) – INPUT SHAFT 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 498: Output Shaft
MX–29 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT OUTPUT SHAFT MX02C–06 COMPONENTS Needle Roller Bearing 3rd Driven Gear 4th Driven Gear Spacer 1st Gear Bearing Inner Race Inner Race 2nd Gear Spacer No.1 Hub Sleeve Needle Roller Output Shaft Bearing Rear Bearing Spring 1st Gear Synchronizer Ring...
Page 499 MX–30 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT MX02D–05 DISASSEMBLY MEASURE 1ST AND 2ND GEARS THRUST CLEAR- ANCE Using a feeler gauge, measure the thrust clearance. Minimum clearance: 1st Gear 1st gear: 0.25 mm (0.0098 – 0.0138 in.) 2nd gear: 0.10 – 0.45 mm (0.0039 – 0.0177 in.) 2nd Gear Maximum clearance: 1st gear: 0.40 mm (0.0157 in.)
Page 500 MX–31 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT 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 501 MX–32 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT MX02E–04 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 502 MX–33 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT 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: 0.35 mm (0.014 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Page 503 MX–34 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT MX02F–07 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. 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 504 MX–35 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT 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 505 MX–36 MANUAL TRANSAXLE (E351) – OUTPUT SHAFT INSTALL OUTPUT SHAFT FRONT BEARING Using SST and a press, install a new output shaft front bearing. 09316–60011 (09316–00071) Z00392 AVENSIS/CORONA SUP (RM781E)
Page 506: Shift And Select Lever Shaft
MX–37 MANUAL TRANSAXLE (E351) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX02I–06 COMPONENTS Control Shaft Cover Oil Seal Dust Boot Shift Interlock Plate Shift Interlock Plate Transmission Oil Baffle No. 1 Compression Spring Snap Ring No. 1 Select Spring Seat Slotted Spring Pin No.
Page 507: Differential Case
MX–38 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX060–04 COMPONENTS Pinion Thrust Washer z Oil Seal Pinion Gear Straight Pin Pinion Shaft Side Gear Side Gear Thrust z Tapered Roller Bearing Washer and Outer Race 106 (1,080, 78) Oil Baffle Diferential Case Speed Sensor...
Page 508 MX–39 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE MX09A–03 DISASSEMBLY Speed sensor drive gear side: REMOVE TAPERED ROLLER BEARING FROM DIF- FERENTIAL CASE Using SST, remove the tapered roller bearing. 09950–00020, 09950–00030, 09950–40011 (09957–04010), 09950–60010 (09951–00530) HINT: Set the claw of SST to the bearing inner race securely. D08953 Remove the speed sensor drive gear.
Page 509 MX–40 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE DISASSEMBLE DIFFERENTIAL CASE Using a pin punch and hammer, drive out the straight pin. Remove the pinion shaft from the differential case. Remove the 2 pinions and side gears with the 4 thrust washers from each gear.
Page 510 MX–41 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE Install the oil baffle. HINT: Install the oil baffle projection into the case side cutout. Using SST and a press, install a new tapered roller bear- ing outer race. 09950–60020 (09951–00890), 09950–70010 (09951–00150) D08957 Using SST and a hammer, drive in a new oil seal.
Page 511 MX–42 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE MX09B–03 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will ensure that the backlash is within the specification.
Page 512 MX–43 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE INSTALL RING GEAR ON DIFFERENTIAL CASE Clean the contact surface of the differential case. Heat the ring gear in boiling water. Case Side Carefully take the ring gear out of the water. After the moisture on the ring gear has completely evapo- rated, quickly install the ring gear to the differential case.
Page 513 MX–44 MANUAL TRANSAXLE (E351) – DIFFERENTIAL CASE INSPECT DIFFERENTIAL TAPERED ROLLER BEAR- ING PRELOAD NOTICE: Perform this only when replacing the tapered roller bearing and outer race of the differential case. Install the differential case assembly to the transaxle case. Install the transmission case to the transaxle case with the 17 bolts.
Page 514: Shift Lever And Control Cable
MX–45 MANUAL TRANSAXLE (E351) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX09C–02 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 516 MANUAL TRANSAXLE (S54, S55) TROUBLESHOOTING ....MX–1 MANUAL TRANSAXLE UNIT ....MX–2 MANUAL TRANSAXLE ASSEMBLY .
Page 518: Troubleshooting
MX–1 MANUAL TRANSAXLE (S54, S55) – TROUBLESHOOTING TROUBLESHOOTING MX030–04 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 parts. Symptom Suspect Area See page...
Page 519: Manual Transaxle Unit
MX–2 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE UNIT MX06M–02 COMPONENTS Air Cleaner Case Assembly with Air Hose RH Drive Shaft Battery 64 (650, 47) Tray 64 (650, 47) Back–Up Light Switch Connector Speed Sensor Connector Engine Rear Mounting 44 (450, 33) Bracket 87 (890, 64)
Page 520 MX–3 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT MX06N–02 REMOVAL REMOVE BATTERY AND AIR CLEANER CASE AS- SEMBLY WITH AIR HOSE REMOVE STARTER Starter Set Bolt Disconnect the connector and wire from the starter. Remove the 2 bolts and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) D02128 DISCONNECT CLUTCH RELEASE CYLINDER AND...
Page 521 MX–4 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT INSTALL ENGINE SUPPORT FIXTURE D02132 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) D02133 REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle side and remove the bolt and bracket.
Page 522 MX–5 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT REMOVE ENGINE MOUNTING CENTER MEMBER Remove the 2 bolts and front transport hook. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) Support the suspension crossmember with a jack. D02165 Remove the 2 hole plugs and hole cover. Remove the 7 bolts and center member.
Page 523 MX–6 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT REMOVE TRANSAXLE Lower engine left side and remove the transaxle from the en- gine. HINT: At the time of installation, please refer to the following items. Align the input shaft with the clutch disc and install the transaxle to the engine.
Page 524 MX–7 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE UNIT MX06O–02 INSTALLATION Installation is in the reverse order of removal (See page MX–3). HINT: After installation, check and inspect items as follows. Front wheel alignment (See Pub. No. RM599E on page SA–4). Do the road test.
Page 525: Manual Transaxle Assembly
MX–8 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY MANUAL TRANSAXLE ASSEMBLY MX034–04 COMPONENTS Release Bearing Straight Screw Plug Retainer 13 (130, 9) 5.4 (55, 48 in.·lbf) Shift and Select Lever L Lock Ball Speed Sensor Assembly Assembly 37 (375, 27) Reverse 29 (300, 22) Restrict Pin...
Page 526 MX–9 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY Reverse Shift Fork Interlock Pin Transaxle Case No.1 Shift Fork Oil Seal No.2 Shift Fork Shaft No.2 Shift Fork Transaxle Case Receiver 7.4 (75, 65 in.·lbf) No.1 Shift Head No.1 Shift Fork Shaft Differential Case Assembly Input Shaft Front Bearing Bearing Lock Plate...
Page 527 MX–10 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY MX035–04 DISASSEMBLY REMOVE RELEASE FORK AND BEARING REMOVE BACK–UP LIGHT SWITCH Torque: 44 N·m (450 kgf·cm, 33 ft·lbf) REMOVE BOLT AND SPEED SENSOR Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) REMOVE RELEASE BEARING RETAINER Remove the 3 bolts and retainer.
Page 528 MX–11 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY REMOVE OUTPUT SHAFT LOCK NUT Unstake the nut. Engage the gear to the double meshing, with the gear into 1st and 3rd or 2nd and 4th. Q02530 Remove the lock nut clockwise and remove it. Install Torque: 123 N·m (1,250 kgf·cm, 90 ft·lbf) HINT:...
Page 529 MX–12 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY MEASURE 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Maximum clearance: 0.048 mm (0.0019 in.) Minimum clearance: 0.009 mm (0.0004 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft.
Page 530 MX–13 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY HINT: At the time of reassembly, please refer to the following item. Using SST and a press, install the No.3 clutch hub assembly. 09612–22011 Remove the 5th gear. REMOVE NEEDLE ROLLER BEARING Q02682 REMOVE REAR BEARING RETAINER Remove the 5 bolts and retainer.
Page 531 MX–14 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY REMOVE REVERSE IDLER GEAR AND SHAFT Pull out the shaft. Remove the idler gear and thrust washer. REMOVE REVERSE SHIFT ARM Shift the fork shaft into reverse. Remove the 2 bolts and pull off the reverse shift arm. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE...
Page 532 MX–15 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY 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. Using a screwdriver, remove the snap ring. HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring.
Page 533 MX–16 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY MX06P–02 INSPECTION INSPECT NO.5 SYNCHRONIZER RING Check 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 534 MX–17 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY Using SST and a press in a new bearing. 09310–35010 Install the bearing lock plate and torque the bolt. Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) Front Z00593 IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL 0 –...
Page 535 MX–18 MANUAL TRANSAXLE (S54, S55) – MANUAL TRANSAXLE ASSEMBLY MX037–04 REASSEMBLY Reassembly is in the reverse order of disassembly (See page MX–10). HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly. NOTICE: When working with FIPG material, you must observe the following items. Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket sur- faces.
Page 536: Input Shaft
MX–19 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT INPUT SHAFT MX038–04 COMPONENTS Spacer Needle Roller Bearing 4th Gear Rear Bearing Snap Ring Synchronizer Ring Synchronizer Ring Shifting Key Input Shaft Snap Ring 3rd Gear Needle Roller Bearing No.2 Hub Sleeve Shifting Key Spring Q02560 AVENSIS/CORONA SUP (RM781E)
Page 537 MX–20 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT MX039–04 DISASSEMBLY INSPECT 3RD AND 4TH GEARS THRUST CLEAR- ANCES Using a feeler gauge, measure each thrust clearance. 3rd Gear Maximum clearance: 3rd gear: 0.35 mm (0.0138 in.) 4th Gear 4th gear: 0.45 mm (0.0177 in.) Minimum clearance: 3rd gear: 0.10 mm (0.0039 in.) Q05793...
Page 538 MX–21 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLER BEAR- Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings. 09950–00020 NOTICE: Be careful not to mistake the 3rd gear synchronizer ring for the 4th gear synchronizer ring.
Page 539 MX–22 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT MX03A–04 INSPECTION INSPECT SYNCHRONIZER RING Check 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 540 MX–23 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT INSPECT INPUT SHAFT Check the input shaft for wear or damage. Using a micrometer, measure the outer diameter of the in- put shaft journal surface. Minimum outer diameter: Part A: 26.987 mm (1.0625 in.) Part B: 32.484 mm (1.2789 in.) Part C: 33.100 mm (1.3031 in.) Part D: 29.987 mm (1.1806 in.)
Page 541 MX–24 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT MX03B–04 REASSEMBLY HINT: Engine Coat all of the sliding and rotating surfaces with gear oil before Side reassembly. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE Install the clutch hub and shifting keys to the hub sleeve. Install the shifting key springs under the shifting keys.
Page 542 MX–25 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT INSTALL SNAP RING Select a snap ring that allows the minimum axial play. Mark Thickness mm (in.) 1.95–2.00 (0.0768–0.0787) 2.00–2.05 (0.0787–0.0807) 2.05–2.10 (0.0807–0.0827) 2.10–2.15 (0.0827–0.0846) 2.15–2.20 (0.0846–0.0866) Z00604 2.20–2.25 (0.0866–0.0886) Using a snap ring expander, install the snap ring. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX–20) INSTALL SYNCHRONIZER RING, NEEDLE ROLLER...
Page 543 MX–26 MANUAL TRANSAXLE (S54, S55) – INPUT SHAFT INSTALL SNAP RING Select a snap ring that allows the minimum axial play. Mark Thickness mm (in.) 2.15–2.20 (0.0846–0.0866) 2.20–2.25 (0.0866–0.0886) 2.25–2.30 (0.0886–0.0906) 2.30–2.35 (0.0906–0.0925) 2.35–2.40 (0.0925–0.0945) SM0050 Using a screwdriver and hammer, tap in the snap ring. INSPECT 4TH GEAR THRUST CLEARANCE (See page MX–20) AVENSIS/CORONA SUP (RM781E)
Page 544: Output Shaft
MX–27 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT OUTPUT SHAFT MX03C–04 COMPONENTS Output Shaft Spacer 1st Gear Needle Roller Bearing Synchronizer Ring No.1 Hub Sleeve Shifting Key Shifting Key Spring No.1 Clutch Hub Needle Roller Bearing Ball Spacer Rear Bearing Synchronizer Ring 2nd Gear 2nd Gear Bushing...
Page 545 MX–28 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT MX03D–03 DISASSEMBLY INSPECT 1ST AND 2ND GEARS THRUST CLEAR- ANCES Using a feeler gauge, measure each thrust clearance. 2nd Gear Maximum clearance: 1st gear: 0.29 mm (0.0114 in.) 1st Gear 2nd gear: 0.34 mm (0.0134 in.) Minimum clearance: 1st gear: 0.10 mm (0.0039 in.) Q05794...
Page 546 MX–29 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL Using a press, remove the No.1 hub sleeve, 1st gear and synchronizer ring. Remove the needle roller bearing and locking ball. Using a screwdriver and hammer, drive out the thrust washer.
Page 547 MX–30 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT MX03E–04 INSPECTION INSPECT 1ST GEAR SYNCHRONIZER RING Check 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 548 MX–31 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT INSPECT SHIFT FORK AND HUB SLEEVE CLEAR- ANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 0.4 mm (0.016 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
Page 549 MX–32 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT MX03F–04 REASSEMBLY HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE Front Install the 3 springs and shifting keys to the clutch hub. Install the hub sleeve to the clutch hub.
Page 550 MX–33 MANUAL TRANSAXLE (S54, S55) – OUTPUT SHAFT INSTALL SYNCHRONIZER RING, 2ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR Install the ball. Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft. Place the synchronizer rings on the 2nd gear.
Page 551: Shift And Select Lever Shaft
MX–34 MANUAL TRANSAXLE (S54, S55) – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT MX03G–04 COMPONENTS Shift and Select Lever Shaft E–ring Select Spring Seat Compression Spring Shift Interlock Plate 6.4 (85, 56 in.·lbf) Compression Spring Dust Boot Washer E–ring Slotted Spring Pin...
Page 552: Differential Case
MX–35 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE DIFFERENTIAL CASE MX03H–04 COMPONENTS Shim Outer Race and Side Bearing Pinion Thrust Washer Ring Gear Pinion Gear Pinion Shaft 83 (850, 61) Side Bearing and Outer Race Side Gear Shim Side Gear Thrust Washer Differential Case Straight Pin Speed Sensor Drive Gear...
Page 553 MX–36 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE MX03I–04 DISASSEMBLY Speed Sensor Drive Gear Side: REMOVE SIDE BEARING FROM DIFFERENTIAL CASE Using SST, remove the bearing from the drive gear side of the case. 09950–00020, 09950–00030 Remove the speed sensor drive gear. REMOVE RING GEAR Q08148 Place matchmarks on the ring gear and case.
Page 554 MX–37 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE Transmission Case Side: IF NECESSARY, REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL Using SST and a hammer, drive out the oil seal from the retainer. 09950–60020 (09951–00680), 09950–70010 (09951–07150) Q08145 Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface.
Page 555 MX–38 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE Transaxle Case Side: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE Using a brass bar and hammer, drive out the bearing out- er race and shim. Place the shim into the case. Using SST and a press, install a new bearing outer race. 09950–60020 (09951–00680), 09950–70010 (09951–07150) Q08184...
Page 556 MX–39 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE MX03J–04 REASSEMBLY ASSEMBLE DIFFERENTIAL CASE Install the correct thrust washers and side gears. Refer to the table below, select thrust washers which will allow that the backlash is within the specification. Try to select washers of the same size for both sides.
Page 557 MX–40 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE INSTALL SIDE BEARING TO DIFFERENTIAL CASE Using SST and a press, install a new side bearing to the transmission case side. 09316–60011 (09316–00011), 09350–32014 (09351–32120) SM0287 Install the speed sensor drive gear to the transaxle case side.
Page 558 MX–41 MANUAL TRANSAXLE (S54, S55) – DIFFERENTIAL CASE Using SST and a torque wrench, measure the preload. 09564–32011 Preload (at starting): 1.0–1.6 N·m (10–16 kgf·cm, 8.7–13.9 in.·lbf) If the preload is not within the specification, remove the trans- mission case side bearing retainer. Select another shim. HINT: The preload will change by approx.
Page 559: Shift Lever And Control Cable
MX–42 MANUAL TRANSAXLE (S54, S55) – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE MX03K–03 COMPONENTS Console Box Assembly Shift Lever Knob Parking Brake Cover Front Ash Receptacle Shift Lever Assembly 12 (120, 9) Clip 4.9 (50, 43in.·lbf) Air Duct Clip Transmission Control Cable Bracket...
Page 560 AUTOMATIC TRANSAXLE (A246E) AUTOMATIC TRANSAXLE SYSTEM ..AX–1 NEUTRAL START SWITCH ....AX–3 VALVE BODY ASSEMBLY ....AX–4 DIFFERENTIAL OIL SEAL .
Page 562: Automatic Transaxle System
AX–1 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX02L–04 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. AVENSIS/CORONA SUP (RM781E)
Page 563 AX–2 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE SYSTEM AX02M–06 OPERATION Forward Clutch (C No.2 One–Way Clutch (F 2nd Coast Brake (B 2nd Brake (B 1st and Reverse Brake (B Direct Clutch (C Front Planetary Gear Unit No.1 One–Way Clutch (F Rear Planetary Gear Unit U/D Planetary Gear Unit U/D Brake (B...
Page 564: Neutral Start Switch
AX–3 AUTOMATIC TRANSAXLE (A246E) – NEUTRAL START SWITCH NEUTRAL START SWITCH AX0PK–02 ON–VEHICLE REPAIR REMOVE LH ENGINE UNDER COVER DISCONNECT SHIFT CABLE FROM CONTROL SHIFT LEVER DISCONNECT NEUTRAL START SWITCH CONNEC- Q08545 REMOVE NEUTRAL START SWITCH Remove the nut, washer and control shaft lever. Pry out the lock washer and remove the manual valve shaft nut.
Page 565: Valve Body Assembly
AX–4 AUTOMATIC TRANSAXLE (A246E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX0PL–02 ON–VEHICLE REPAIR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET Remove the 18 bolts. NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the oil pan assembly.
Page 566 AX–5 AUTOMATIC TRANSAXLE (A246E) – VALVE BODY ASSEMBLY REMOVE MANUAL DETENT SPRING Remove the bolt and manual detent spring. F00673 REMOVE VALVE BODY Remove the 17 bolts. D08579 While disconnecting the manual valve connecting rod from the manual valve lever, remove the valve body with the manual valve together.
Page 567 AX–6 AUTOMATIC TRANSAXLE (A246E) – VALVE BODY ASSEMBLY INSTALL OIL STRAINER Install the oil strainer with the 3 bolts. Bolt length: A bolt: 12 mm (0.47 in.) B bolt: 20 mm (0.79 in.) Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) D08576 INSTALL MAGNETS IN OIL PAN INSTALL OIL PAN AND GASKET...
Page 568: Differential Oil Seal
AX–7 AUTOMATIC TRANSAXLE (A246E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX02R–06 ON–VEHICLE REPAIR DRAIN ATF REMOVE LH AND RH ENGINE UNDER COVERS REMOVE LH AND RH DRIVE SHAFTS (See page SA–3) F00483 REMOVE LH AND RH OIL SEAL Using SST, drive out the oil seal. 09308–00010 Z02840 INSTALL LH SIDE OIL SEAL...
Page 569: Shift Lock System
AX–8 AUTOMATIC TRANSAXLE (A246E) – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM AX10R–01 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Control Computer D10026 AVENSIS/CORONA SUP (RM781E)
Page 570 AX–9 AUTOMATIC TRANSAXLE (A246E) – SHIFT LOCK SYSTEM AX10S–01 INSPECTION 5 (IG) 1 (ACC) LHD: 4 (KLS+) INSPECT SHIFT LOCK CONTROL COMPUTER Using a voltmeter, measure the voltage at each terminal. 3 (E) HINT: Do not disconnect the shift lock control computer connector. 2 (STP) Wire harness side D00758...
Page 571 AX–10 AUTOMATIC TRANSAXLE (A246E) – SHIFT LOCK SYSTEM INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. – Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 12.5 – 16.5 Ω If the resistance value is not as specified, replace the solenoid. D08869 Provide the battery voltage between the terminals.
Page 572: Floor Shift Assembly (Lhd
AX–11 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) FLOOR SHIFT ASSEMBLY (LHD) AX02U–07 COMPONENTS Parking Brake Cover 12 (120, 9) Clip Shift Control Cable Shift Lever Assembly Rear Console Box N·m (kgf·cm, ft·lbf) : Specified torque D10190 AVENSIS/CORONA SUP (RM781E)
Page 573 AX–12 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) Pattern Select Switch Position Indicator Shift Lever Knob Sub–assembly Upper Housing Spring Shift Lever Knob Sleeve Shift Lever Button Detent Rod Position Indicator Slide Cover O/D Main Switch Position Spring Indicator Plate Position Indicator Lower Housing Shift Lever Knob Cover...
Page 574 AX–13 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) AX10T–01 REMOVAL REMOVE REAR CONSOLE (See page BO–8) REMOVE SHIFT LEVER ASSEMBLY Disconnect the 3 connectors and wire harness. Remove the clip and disconnect the shift control cable. Remove the 4 bolts and floor shift assembly. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D02081 AVENSIS/CORONA SUP (RM781E)
Page 575 AX–14 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) AX0C5–03 DISASSEMBLY REMOVE O/D MAIN SWITCH TERMINAL Remove the O/D main switch connector from the shift le- ver plate. Disengage the secondary locking device. Release the locking lug of the terminals 2 and 4, and pull the terminals out from the rear.
Page 576 AX–15 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) REMOVE SHIFT LEVER SUB–ASSEMBLY Using a screwdriver and a hammer, remove the control shaft. Remove the shift lever sub–assembly. F00683 DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY Measure the distance ”A” between the lower edge of the shift lever knob sleeve and the upper edge of the shift le- ver sub–assembly.
Page 577 AX–16 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) AX0C6–03 REASSEMBLY INSTALL COLLARS INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT ASSEMBLE SHIFT LEVER SUB–ASSEMBLY : Apply MP Grease Apply MP grease on the compression spring, the detent rod and the shift lever sub–assembly. Install the spring and the detent rod to shift lever sub–as- sembly.
Page 578 AX–17 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) Press the pin with a hammer. Shift Lever Sub–assembly A: 10.0 – 10.4 mm (0.39 – 0.41 in.) NOTICE: When pressing in the grooved pin, if doing it at the place other than the notch, the shift lever sub–assembly might be damaged.
Page 579 AX–18 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) ASSEMBLE INDICATOR HOUSING Install the position indicator plate. Install the position indicator slide cover. Install the spring and shift lock release button. Install the position indicator lower housing. Install the pattern select switch. NOTICE: Do not make indicator housing dirty with MP grease.
Page 580 AX–19 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (LHD) AX02Y–07 INSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Installation is in the reverse order of removal (See page AX–13). HINT: After installation, adjust shift lever ranges (See page DI–3) and inspect shift lever operation. When shifting it to each range, make sure that the shifting lever moves smoothly, can be moderately operated and the range indicator displays correctly.
Page 581: Floor Shift Assembly (Rhd
AX–20 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) FLOOR SHIFT ASSEMBLY (RHD) AX01B–03 COMPONENTS 12 (120, 9) Clip Rear Console Box Shift Control Cable Shift Lever Assembly Parking Brake Cover N·m (kgf·cm, ft·lbf) : Specified torque D02091 AVENSIS/CORONA SUP (RM781E)
Page 582 AX–21 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) Shift Lever Button Spring Pattern Select Switch Shift Lever Knob Position Indicator Plate Position Indicator Upper Housing O/D Main Position Indicator Detent Rod Bulb Switch Slide Cover Shift Lever Knob Cover Indicator Light Wire Spring Stopper Pin...
Page 583 AX–22 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) AX10U–01 REMOVAL REMOVE REAR CONSOLE (See page BO–8) REMOVE FLOOR SHIFT ASSEMBLY Disconnect the connectors. Remove the clip and disconnect the shift control cable. Remove the 4 bolts and shift lever assembly. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D02093 AVENSIS/CORONA SUP (RM781E)
Page 584 AX–23 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) AX10V–01 DISASSEMBLY REMOVE O/D MAIN SWITCH TERMINAL Remove O/D main switch connector from the shift lever plate. Disengage the secondary locking device. Disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the rear.
Page 585 AX–24 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) REMOVE SHIFT LEVER SUB–ASSEMBLY Using an extension bar and hammer, remove the control shaft. Remove the shift lever sub–assembly. D02095 DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY Remove the Detent roller holder. Remove the Compression spring. D02096 REMOVE COLLARS Using an extension bar and hammer, remove the 4 collars.
Page 586 AX–25 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) AX10W–01 REASSEMBLY INSTALL COLLARS ASSEMBLE SHIFT LEVER SUB–ASSEMBLY : Apply MP Grease Apply the MP grease to the detent roller holder, compres- sion spring and shift lever sub–assembly. Install the compression spring to the detent roller holder. Install the detent roller holder with the compression spring to the shift lever sub–assembly.
Page 587 AX–26 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY HINT: Apply MP grease to the shift lever knob button. Install the O/D main switch. Install the shift lever button and spring. Install the shift lever knob cover. Install the shift lever knob sub–assembly and 2 screws.
Page 588 AX–27 AUTOMATIC TRANSAXLE (A246E) – FLOOR SHIFT ASSEMBLY (RHD) AX01F–03 INSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Installation is in the reverse order of removal (See page AX–22). HINT: After installation, adjust shift lever ranges (See page DI–3) and inspect shift lever operation. When shifting it to each range, make sure that the shifting lever moves smoothly, can be moderately operated and the range indicator displays correctly.
Page 589: Automatic Transaxle Unit
AX–28 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX02Z–04 COMPONENTS Battery RH Drive Shaft Air Cleaner Assembly 87 (890, 64) 13 (130, 9) 39 (400, 29) Torque Converter Clutch 25 (250, 18) 64 (650, 47) 64 (650, 47) 28 (290, 21) 46 (470, 34) 52 (530, 38)
Page 590 AX–29 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE UNIT AX10X–01 REMOVAL REMOVE BATTERY REMOVE AIR CLEANER REMOVE GROUND CABLE Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE SIDE Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) REMOVE UPPER SIDE STARTER MOUNTING BOLT Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) DISCONNECT VEHICLE SPEED SENSOR CONNEC-...
Page 591 AX–30 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE UNIT Remove the 9 bolts, 3 grommets, front center member protector and front center member. Torque: A: 73 N·m (740 kgf·cm, 54 ft·lbf) B: 39 N·m (400 kgf·cm, 29 ft·lbf) C: 72 N·m (740 kgf·cm, 53 ft·lbf) D02064 REMOVE STARTER Remove the nut and cable, and disconnect the connector.
Page 592 AX–31 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE UNIT JACK UP TRANSAXLE F00479 REMOVE TRANSAXLE Remove the hole plug. Turn the crankshaft to gain access and remove the 6 bolts holding the crankshaft pulley set bolt with a wrench. Torque: 28 N·m (290 kgf·cm, 21 ft·lbf) HINT: At the time of installation, please refer to the following item.
Page 593 AX–32 AUTOMATIC TRANSAXLE (A246E) – AUTOMATIC TRANSAXLE UNIT AX031–05 INSTALLATION CHECK TORQUE CONVERTER INSTALLATION Using calipers and a straight edge, measure the distance be- tween the installed surface and the front surface of the trans- axle housing. Correct distance: More than 15.5 mm (0.610 in.) TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX–29).
Page 594: Torque Converter And Drive Plate
AX–33 AUTOMATIC TRANSAXLE (A246E) – TORQUE CONVERTER AND DRIVE PLATE TORQUE CONVERTER AND DRIVE PLATE AX032–04 INSPECTION INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. 09350–32014 (09351–32010) Install SST so that it fits in the notch of the converter hub AT0953 and outer race of the one–way clutch.
Page 596 AUTOMATIC TRANSAXLE (U240E) AUTOMATIC TRANSAXLE SYSTEM ..AX–1 SPEED SENSOR ......AX–3 ATF TEMPERATURE SENSOR .
Page 598: Automatic Transaxle System
AX–1 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM AX0LF–01 PRECAUTION If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. AVENSIS/CORONA SUP (RM781E)
Page 599 AX–2 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE SYSTEM AX0LG–03 OPERATION 1st & Reverse Brake (B Forward Clutch (C 2nd Brake (B Direct Clutch (C No.1 One–way Clutch (F U/D Brake (B U/D One–way Clutch (F U/D Clutch (C D05891 f ... Operating Shift lever range Gear range Parking...
Page 600: Speed Sensor
AX–3 AUTOMATIC TRANSAXLE (U240E) – SPEED SENSOR SPEED SENSOR AX0LI–03 ON–VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR REMOVE COUNTER GEAR SENSOR Remove the bolt and counter gear speed sensor. D05876 Remove the O–ring from the counter gear speed sensor. INSTALL COUNTER GEAR SPEED SENSOR O–ring Coat a new O–ring with ATF and install it to the counter...
Page 601: Atf Temperature Sensor
AX–4 AUTOMATIC TRANSAXLE (U240E) – ATF TEMPERATURE SENSOR ATF TEMPERATURE SENSOR AX0LJ–03 ON–VEHICLE REPAIR DISCONNECT SOLENOID CONNECTOR REMOVE LH ENGINE UNDER COVER D05886 REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the 18 bolts, and carefully remove the oil pan assem- bly.
Page 602 AX–5 AUTOMATIC TRANSAXLE (U240E) – ATF TEMPERATURE SENSOR INSTALL OIL STRAINER Coat a new O–ring with ATF. Install the O–ring to the oil strainer. D05880 Install the oil strainer with the 3 bolts. Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf) D05879 INSTALL OIL PAN Install the oil pan and a new gasket with the 18 bolts.
Page 603: Neutral Start Switch
AX–6 AUTOMATIC TRANSAXLE (U240E) – NEUTRAL START SWITCH NEUTRAL START SWITCH AX0LK–03 ON–VEHICLE REPAIR REMOVE AIR CLEANER ASSEMBLY DISCONNECT NEUTRAL START SWITCH CONNEC- D05911 REMOVE NEUTRAL START SWITCH Remove the nut. D05912 Remove the nut, washer and control shift lever. D05913 Using a screwdriver, pry off the lock plate.
Page 604 AX–7 AUTOMATIC TRANSAXLE (U240E) – NEUTRAL START SWITCH Remove the 2 bolts and pull out the neutral start switch. INSTALL AND ADJUST NEUTRAL START SWITCH Install the neutral start switch with the 2 bolts. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) Install a new lock plate and nut.
Page 605: Valve Body Assembly
AX–8 AUTOMATIC TRANSAXLE (U240E) – VALVE BODY ASSEMBLY VALVE BODY ASSEMBLY AX0LM–03 ON–VEHICLE REPAIR REMOVE LH ENGINE UNDER COVER REMOVE DRAIN PLUG AND DRAIN ATF REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove the 18 bolts, and carefully remove the oil pan assem- bly.
Page 606 AX–9 AUTOMATIC TRANSAXLE (U240E) – VALVE BODY ASSEMBLY REMOVE VALVE BODY Remove the 17 bolts and valve body. NOTICE: Be careful not to drop the check valve body, spring and ac- cumulator piston. D02935 REMOVE CHECK BALL BODY AND SPRING D02936 REMOVE 2 APPLY GASKETS D02937...
Page 607 AX–10 AUTOMATIC TRANSAXLE (U240E) – VALVE BODY ASSEMBLY INSTALL CHECK VALVE AND SPRING D02936 INSTALL VALVE BODY Align the groove of the manual valve with the pin of the manual valve lever. Temporarily install the valve body with the 17 bolts. Bolt length: Bolt A: 25 mm (0.98 in.) Bolt B: 41 mm (1.61 in.)
Page 608 AX–11 AUTOMATIC TRANSAXLE (U240E) – VALVE BODY ASSEMBLY Install the oil strainer with the 3 bolts. Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf) D05879 INSTALL MAGNET IN OIL PAN Install the 3 magnets in the oil pan, as shown in the illustration. D02940 INSTALL OIL PAN Install the oil pan and a new gasket with the 18 bolts.
Page 609: Differential Oil Seal
AX–12 AUTOMATIC TRANSAXLE (U240E) – DIFFERENTIAL OIL SEAL DIFFERENTIAL OIL SEAL AX0LN–02 ON–VEHICLE REPAIR DRAIN ATF REMOVE LH AND RH DRIVE SHAFTS (See page SA–3) D07261 REMOVE LH AND RH SIDE OIL SEAL Using SST, drive out both the side oil seals. 09308–10010 D03284 INSTALL LH SIDE OIL SEAL...
Page 610: Shift Lock System
AX–13 AUTOMATIC TRANSAXLE (U240E) – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM AX10Y–01 LOCATION Key Interlock Solenoid Stop Light Switch Shift Lock Control Computer D10026 AVENSIS/CORONA SUP (RM781E)
Page 611 AX–14 AUTOMATIC TRANSAXLE (U240E) – SHIFT LOCK SYSTEM AX10Z–01 INSPECTION 5 (IG) 1 (ACC) LHD: 4 (KLS+) INSPECT SHIFT LOCK CONTROL COMPUTER Using a voltmeter, measure the voltage at each terminal. 3 (E) HINT: Do not disconnect the shift lock control computer connector. 2 (STP) Wire harness side D00758...
Page 612 AX–15 AUTOMATIC TRANSAXLE (U240E) – SHIFT LOCK SYSTEM INSPECT KEY INTERLOCK SOLENOID Disconnect the solenoid connector. – Using an ohmmeter, measure the resistance between the terminals. Standard resistance: 12.5 – 16.5 Ω If the resistance value is not as specified, replace the solenoid. D08869 Provide the battery voltage between the terminals.
Page 613: Floor Shift Assembly (Lhd
AX–16 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) FLOOR SHIFT ASSEMBLY (LHD) AX02U–08 COMPONENTS Parking Brake Cover 12 (120, 9) Clip Shift Control Cable Shift Lever Assembly Rear Console Box N·m (kgf·cm, ft·lbf) : Specified torque D10190 AVENSIS/CORONA SUP (RM781E)
Page 614 AX–17 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) Pattern Select Switch Position Indicator Shift Lever Knob Sub–assembly Upper Housing Spring Shift Lever Knob Sleeve Shift Lever Button Detent Rod Position Indicator Slide Cover O/D Main Switch Position Spring Indicator Plate Position Indicator Lower Housing Shift Lever Knob Cover...
Page 615 AX–18 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) AX05L–03 REMOVAL REMOVE REAR CONSOLE (See page BO–8) REMOVE SHIFT LEVER ASSEMBLY Disconnect the 3 connectors and wire harness. Remove the clip and disconnect the shift control cable. Remove the 4 bolts and floor shift assembly. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D02081 AVENSIS/CORONA SUP (RM781E)
Page 616 AX–19 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) AX0C5–04 DISASSEMBLY REMOVE O/D MAIN SWITCH TERMINAL Remove the O/D main switch connector from the shift le- ver plate. Disengage the secondary locking device. Release the locking lug of the terminals 2 and 4, and pull the terminals out from the rear.
Page 617 AX–20 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) REMOVE SHIFT LEVER SUB–ASSEMBLY Using a screwdriver and a hammer, remove the control shaft. Remove the shift lever sub–assembly. F00683 DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY Measure the distance ”A” between the lower edge of the shift lever knob sleeve and the upper edge of the shift le- ver sub–assembly.
Page 618 AX–21 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) AX0C6–04 REASSEMBLY INSTALL COLLARS INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT ASSEMBLE SHIFT LEVER SUB–ASSEMBLY : Apply MP Grease Apply MP grease on the compression spring, the detent rod and the shift lever sub–assembly. Install the spring and the detent rod to shift lever sub–as- sembly.
Page 619 AX–22 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) Press the pin with a hammer. Shift Lever Sub–assembly A: 10.0 – 10.4 mm (0.39 – 0.41 in.) NOTICE: When pressing in the grooved pin, if doing it at the place other than the notch, the shift lever sub–assembly might be damaged.
Page 620 AX–23 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) ASSEMBLE INDICATOR HOUSING Install the position indicator plate. Install the position indicator slide cover. Install the spring and shift lock release button. Install the position indicator lower housing. Install the pattern select switch. NOTICE: Do not make indicator housing dirty with MP grease.
Page 621 AX–24 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (LHD) AX02Y–08 INSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Installation is in the reverse order of removal (See page AX–18). HINT: After installation, adjust shift lever ranges (See page DI–62) and inspect shift lever operation. When shifting it to each range, make sure that the shifting lever moves smoothly, can be moderately operated and the range indicator displays correctly.
Page 622: Floor Shift Assembly (Rhd
AX–25 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) FLOOR SHIFT ASSEMBLY (RHD) AX05N–02 COMPONENTS 12 (120, 9) Clip Rear Console Box Shift Control Cable Shift Lever Assembly Parking Brake Cover N·m (kgf·cm, ft·lbf) : Specified torque D02091 AVENSIS/CORONA SUP (RM781E)
Page 623 AX–26 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) Shift Lever Button Spring Pattern Select Switch Shift Lever Knob Position Indicator Plate Position Indicator Upper Housing O/D Main Position Indicator Detent Rod Bulb Switch Slide Cover Shift Lever Knob Cover Indicator Light Wire Spring Stopper Pin...
Page 624 AX–27 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) AX05O–02 REMOVAL REMOVE REAR CONSOLE (See page BO–8) REMOVE FLOOR SHIFT ASSEMBLY Disconnect the connectors. Remove the clip and disconnect the shift control cable. Remove the 4 bolts and shift lever assembly. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) D02093 AVENSIS/CORONA SUP (RM781E)
Page 625 AX–28 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) AX110–01 DISASSEMBLY REMOVE O/D MAIN SWITCH TERMINAL Remove O/D main switch connector from the shift lever plate. Disengage the secondary locking device. Disengage the locking lug of the terminals 2 and 4, and pull the terminals out from the rear.
Page 626 AX–29 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) REMOVE SHIFT LEVER SUB–ASSEMBLY Using an extension bar and hammer, remove the control shaft. Remove the shift lever sub–assembly. D02095 DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY Remove the Detent roller holder. Remove the Compression spring. D02096 REMOVE COLLARS Using an extension bar and hammer, remove the 4 collars.
Page 627 AX–30 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) AX05Q–02 REASSEMBLY INSTALL COLLARS ASSEMBLE SHIFT LEVER SUB–ASSEMBLY : Apply MP Grease Apply the MP grease to the detent roller holder, compres- sion spring and shift lever sub–assembly. Install the compression spring to the detent roller holder. Install the detent roller holder with the compression spring to the shift lever sub–assembly.
Page 628 AX–31 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY HINT: Apply MP grease to the shift lever knob button. Install the O/D main switch. Install the shift lever button and spring. Install the shift lever knob cover. Install the shift lever knob sub–assembly and 2 screws.
Page 629 AX–32 AUTOMATIC TRANSAXLE (U240E) – FLOOR SHIFT ASSEMBLY (RHD) AX05R–03 INSTALLATION INSTALL FLOOR SHIFT ASSEMBLY Installation is in the reverse order of removal (See page AX–27). HINT: After installation, adjust shift lever ranges (See page DI–62) and inspect shift lever operation. When shifting it to each range, make sure that the shifting lever moves smoothly, can be moderately operated and the range indicator displays correctly.
Page 630: Automatic Transaxle Unit
AX–33 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE UNIT AUTOMATIC TRANSAXLE UNIT AX064–02 COMPONENTS Battery Air Cleaner Assembly RH Drive Shaft 87 (890, 64) 64 (650, 47) 64 (650, 47) Torque Converter Clutch 18 (185, 13) 41 (420, 30) Ground Cable 46 (470, 34) 52 (530, 38) 87 (890, 64)
Page 631 AX–34 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE UNIT AX111–01 REMOVAL REMOVE BATTERY REMOVE AIR CLEANER ASSEMBLY REMOVE STARTER Remove the nut and disconnect the connector. Remove the 2 bolts, bracket and starter. Torque: 39 N·m (400 kgf·cm, 29 ft·lbf) DISCONNECT GROUND CABLE Torque: 18 N·m (185 kgf·cm, 13 ft·lbf) D09912 REMOVE 4 UPPER SIDE TRANSAXLE MOUNTING...
Page 632 AX–35 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE UNIT DISCONNECT SHIFT CONTROL CABLE Remove the nut, clip and disconnect the shift control cable. Torque: 12 N·m (120 kgf·cm, 9 ft·lbf) DISCONNECT NEUTRAL START SWITCH CONNEC- TOR AND SOLENOID CONNECTOR DISCONNECT VEHICLE SPEED SENSOR CONNEC- D09914 REMOVE EXHAUST FRONT PIPE Disconnect the oxygen sensor connector.
Page 633 AX–36 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE UNIT SUPPORT TRANSAXLE D02524 REMOVE ENGINE REAR MOUNTING BOLT Torque: 87 N·m (890 kgf·cm, 64 ft·lbf) D10022 REMOVE ENGINE REAR MOUNTING BRACKET Remove the 3 bolts and engine rear mounting bracket. Torque: 64 N·m (650 kgf·cm, 47 ft·lbf) D02044 REMOVE TRANSAXLE Turn the crankshaft to gain access and remove the 6 bolts...
Page 634 AX–37 AUTOMATIC TRANSAXLE (U240E) – AUTOMATIC TRANSAXLE UNIT AX066–02 INSTALLATION CHECK TORQUE CONVERTER INSTALLATION Using a scale and a straight edge, measure the distance from the installation surface to the front surface of the transaxle housing. Correct distance: More than 12.75 mm (0.502 in.) TRANSAXLE INSTALLATION Installation is in the reverse order of removal (See page AX–34).
Page 635: Torque Converter And Drive Plate
AX–38 AUTOMATIC TRANSAXLE (U240E) – TORQUE CONVERTER AND DRIVE PLATE TORQUE CONVERTER AND DRIVE PLATE AX067–02 INSPECTION INSPECT ONE–WAY CLUTCH Install SST into the inner race of the one–way clutch. 09350–32014 (09351–32010) Install SST so that it fits in the notch of the converter hub AT0953 and outer race of the one–way clutch.
Page 636 SUSPENSION AND AXLE FRONT DRIVE SHAFT ....SA–1 FRONT SHOCK ABSORBER ....SA–13 REFER TO FOLLOWING REPAIR MANUALS: Manual Name...
Page 638 SA–1 SUSPENSION AND AXLE – FRONT DRIVE SHAFT FRONT DRIVE SHAFT SA109–03 COMPONENTS 1AZ–FSE 1ZZ–FE, 1AZ–FSE Center Bearing Bracket RH Drive Shaft 64 (650, 47) 1ZZ–FE Center Bearing Bracket 3ZZ–FE 64 (650, 47) RH Drive Shaft z Snap Ring z Snap Ring 1ZZ–FE, 3ZZ–FE LH Drive Shaft 1AZ–FSE...
Page 639 SA–2 SUSPENSION AND AXLE – FRONT DRIVE SHAFT Outboard Joint Shaft z Boot Dynamic Damper Dynamic Damper Clamp z Boot Clamp z Boot z Snap Ring Tripod Straight Pin z Snap Ring 3ZZ–FE z Snap Ring 1ZZ–FE RH Inboard Joint Shaft Bearing Case z Snap Ring z Dust Cover...
Page 640 SA–3 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA10A–03 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 641 SA–4 SUSPENSION AND AXLE – FRONT DRIVE SHAFT 3ZZ–FE engine: REMOVE DRIVE SHAFT Using SST, remove the drive shaft. 09520–01010, 09520–24010 (09520–32040) Using a screwdriver, remove the snap ring. HINT: At the time of installation, please refer to the following items. Apply gear oil to the inboard joint shaft and differential case sliding surface.
Page 642 SA–5 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA10B–03 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 643 SA–6 SUSPENSION AND AXLE – FRONT DRIVE SHAFT REMOVE DYNAMIC DAMPER Using a side cutter, cut the dynamic damper clamp and re- move it. Remove the dynamic damper. REMOVE OUTBOARD JOINT BOOT NOTICE: Do not disassemble the outboard joint. REMOVE DUST COVER RH drive shaft of 3ZZ–FE engine and LH drive shaft: Using SST and a press, remove the dust cover from the inboard joint shaft.
Page 644 SA–7 SUSPENSION AND AXLE – FRONT DRIVE SHAFT Using a press, remove the bearing. SA1451 AVENSIS/CORONA SUP (RM781E)
Page 645 SA–8 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA10C–03 REASSEMBLY RH drive shaft of 1ZZ–FE and 1AZ–FSE engine: 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 646 SA–9 SUSPENSION AND AXLE – FRONT DRIVE SHAFT RH drive shaft of 1ZZ–FE and 1AZ–FSE engine: 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 647 SA–10 SUSPENSION AND AXLE – FRONT DRIVE SHAFT INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, pack the outboard joint shaft and boot with grease in the boot kit. Grease capacity: (Color = Black) 85 – 105 g (3.00 – 3.70 oz.) INSTALL INBOARD JOINT SHAFT TO OUTBOARD JOINT SHAFT Pack the inboard joint shaft and boot with grease in the...
Page 648 SA–11 SUSPENSION AND AXLE – FRONT DRIVE SHAFT RH drive shaft of 3ZZ–FE engine: ASSEMBLE DAMPER CLAMP Make sure that the dynamic damper is on the shaft groove. Set the distance, as described below. Distance: 432.1 ± 2.0 mm (17.012 ± 0.079 in.) Secure the clamp onto the damper.
Page 649 SA–12 SUSPENSION AND AXLE – FRONT DRIVE SHAFT SA02Z–04 INSTALLATION Installation is in the reverse order of removal (See page SA–3). HINT: After installation, check the ABS speed sensor signal and front wheel alignment (See Pub. No. RM599E on page SA–4). AVENSIS/CORONA SUP (RM781E)
Page 650 SA–13 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER FRONT SHOCK ABSORBER SA10J–06 COMPONENTS 47 (475, 34) 80 (820, 59) Suspension Support Dust Seal Spring Upper Seat Upper Insulator Coil Spring Shock Absorber with Coil Spring Spring Bumper ABS Speed Sensor Wire Harness Lower Insulator 5.5 (55, 48 in.·lbf)
Page 651 SA–14 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA10K–03 REMOVAL REMOVE FRONT WHEEL Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf) DISCONNECT ABS SPEED SENSOR WIRE HARNESS CLAMPS FROM SHOCK ABSORBER Remove the bolt and disconnect the ABS speed sensor wire harness clamps.
Page 652 SA–15 SUSPENSION AND AXLE – FRONT SHOCK ABSORBER SA10P–05 INSTALLATION Installation is in the reverse order of removal (See page SA–14). HINT: After installation, check the front wheel alignment (See Pub. No. RM599E on page SA–4). AVENSIS/CORONA SUP (RM781E)
Page 654 BRAKE BRAKE PEDAL ......BR–1 REFER TO FOLLOWING REPAIR MANUALS: Manual Name Pub. No. AVENSIS/CORONA Chassis and Body Repair Manual RM599E AVENSIS/CORONA Chassis and Body Repair Manual RM698E...
Page 656 BR–1 BRAKE – BRAKE PEDAL BRAKE PEDAL Stop Light Switch BR0KI–06 ON–VEHICLE INSPECTION CHECK PEDAL HEIGHT Pedal height from asphalt sheet: (LHD) 147.0 – 157.0 mm (5.787 – 6.181 in.) (RHD) 149.5 – 159.5 mm (5.886 – 6.280 in.) If the pedal height is incorrect, adjust it. RHD: IF NECESSARY, ADJUST PEDAL HEIGHT Disconnect the connector from the stop light switch.
Page 657 BR–2 BRAKE – BRAKE PEDAL CHECK PEDAL RESERVE DISTANCE Pedal Reserve Distance Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): LHD Gasoline engine (w/o ABS) More than 70 mm (2.76 in.)
Page 658 STEERING DRIVE BELT ......SR–1 POWER STEERING FLUID ....SR–2 TILT STEERING COLUMN .
Page 660 SR–1 STEERING – DRIVE BELT DRIVE BELT SR08H–06 INSPECTION INSPECT DRIVE BELT Visually check the drive belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. P06717 If the missing chunks from the ribs are found on the drive belt, it should be replaced.
Page 661 SR–2 STEERING – POWER STEERING FLUID POWER STEERING FLUID SR08I–07 BLEEDING CHECK FLUID LEVEL (See page SR–3) JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS TURN STEERING WHEEL With the engine stopped, turn the steering wheel slowly from lock to lock several times.
Page 662 SR–3 STEERING – POWER STEERING FLUID SR08J–05 INSPECTION CHECK FLUID LEVEL Keep the vehicle level. COLD With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON® II or III HINT: R11740 Check that the fluid level is within the HOT LEVEL range on the reservoir.
Page 663 SR–4 STEERING – POWER STEERING FLUID CHECK STEERING FLUID PRESSURE Disconnect the pressure feed tube from the PS vane pump. (1ZZ–FE, 3ZZ–FE Engines: See page SR–10) (1AZ–FSE Engine: See page SR–21) Connect SST, as shown in the illustration below. 09640–10010 (09641–01010, 09641–01030, 09641–01060) NOTICE: Check that the valve of the SST is in the open position.
Page 664 SR–5 STEERING – POWER STEERING FLUID With the engine idling, close the valve of the SST and ob- serve the reading on the SST. Minimum fluid pressure: reservoir 1ZZ–FE, 3ZZ–FE Engines: 8,300 kPa (85 kgf/cm , 1209 psi) PS Gear Closed 1AZ–FSE Engine: 8,800 kPa (90 kgf/cm...
Page 665 SR–6 STEERING – TILT STEERING COLUMN TILT STEERING COLUMN SR0IB–02 COMPONENTS HINT: If the steering column assembly (w/ VSC) is removed or replaced, calibrate the steering angle sensor zero point (See page DI–171). Instrument Cluster Finish Panel Steering Wheel Pad 50 (510, 37) Column Upper Cover Torx Screw...
Page 666 SR–7 STEERING – TILT STEERING COLUMN w/ Engine Immobiliser System: w/ Shift Lock System: Transponder Key Computer Assembly Key Inter Lock Solenoid Transponder Key Computer Case Key Cylinder Column Upper Bracket Key Unlock Warning Switch Column Upper Clamp Ignition Switch z Tapered–head Bolt w/ VSC: Steering Column Assembly...
Page 667 SR–8 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0YO–05 COMPONENTS Pressure Feed Tube 7.8 (80, 69 in.·lbf) 44 (450, 33) *37 (375, 27) Oil Pressure Switch Connector Suction Hose PS Vane Pump Assembly Clip 37 (370, 27) Drive Belt...
Page 668 SR–9 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) Pressure Port Union 69 (700, 51) z O–Ring Flow Control Valve Oil Pressure Switch 21 (210, 15) Spring Suction Port Union z O–Ring 12 (120, 9) 44 (440, 32) Heat Insulator Front Housing z Oil Seal Pump Rear Bracket...
Page 669 SR–10 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0YP–02 REMOVAL REMOVE ENGINE UNDER COVER RH Remove the 5 bolts and engine under cover RH. REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt. Drive Belt Tensioner Arm F08868...
Page 670 SR–11 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0VS–07 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. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less F13466...
Page 671 SR–12 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0VT–07 INSPECTION MEASURE OIL CLEARANCE BETWEEN VANE PUMP Bushing SHAFT AND BUSHING Using a micrometer and a caliper gauge, measure the oil clear- ance. Standard clearance: 0.021 – 0.043 mm (0.0008 – 0.0017 in.) Front Housing Maximum clearance: 0.07 mm (0.0028 in.) Vane Pump Shaft...
Page 672 SR–13 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring. Inscribed mark: 0, 1, 2, 3, or 4 HINT: There are 5 vane plate lengths corresponding to the following vane pump rotor and cam ring marks:...
Page 673 SR–14 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 35.8 mm (1.409 in.) If it is not within the specification, replace the spring. Vernier Calipers R08702 AVENSIS/CORONA SUP (RM781E)
Page 674 SR–15 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0VU–07 REPLACEMENT NOTICE: Vinyl Tape When using a vise, do not overtighten it. IF NECESSARY, REPLACE OIL SEAL Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the bushing of the front housing.
Page 675 SR–16 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0VV–07 REASSEMBLY NOTICE: When using a vise, do not overtighten it. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID (See page SR–8) INSTALL VANE PUMP SHAFT WITH VANE PUMP PULLEY INSTALL SIDE PLATE Coat 2 new O–rings with power steering fluid, and install them to the side plate.
Page 676 SR–17 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) INSTALL OIL PRESSURE SWITCH Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION Install the spring. Install the flow control valve facing in the correct direction (See page SR–8).
Page 677 SR–18 STEERING – POWER STEERING VANE PUMP (1ZZ–FE, 3ZZ–FE) SR0YQ–02 INSTALLATION INSTALL PS VANE PUMP ASSEMBLY Install the PS vane pump assembly with the 2 pump assembly set bolts and nuts. Torque: 37 N·m (370 kgf·cm, 27 ft·lbf) CONNECT OIL PRESSURE SWITCH CONNECTOR NOTICE: Be careful to prevent oil from being attached to the connec- tor.
Page 678 SR–19 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) POWER STEERING VANE PUMP (1AZ–FSE) SR19E–02 COMPONENTS Union Bolt 52 (530, 38) z Gasket Oil Pressure Switch Suction Hose Pressure Feed Tube Clip PS Vane Pump Assembly 50 (510, 37) Drive Belt Engine Under Cover RH N·m (kgf·cm, ft·lbf) : Specified torque z Non–reusable part...
Page 679 SR–20 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) Pressure Port Union 69 (700, 51) z O–Ring Flow Control Valve Oil Pressure Switch 21 (210, 15) Spring z O–Ring Suction Port Union 12 (120, 9) Vane Pump Shaft with Vane Pump Pulley Front Housing z Oil Seal 22 (220, 16)
Page 680 SR–21 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR1C8–01 REMOVAL REMOVE ENGINE UNDER COVER RH Remove the 5 bolts and engine under cover RH. REMOVE DRIVE BELT Using SST, loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt. 09249–63010 F13071 DISCONNECT SUCTION HOSE...
Page 681 SR–22 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR0VS–08 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. Using a torque wrench, check the pump rotating torque. Rotating torque: 0.27 N·m (2.8 kgf·cm, 2.4 in.·lbf) or less F11943...
Page 682 SR–23 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR0VT–08 INSPECTION MEASURE OIL CLEARANCE BETWEEN VANE PUMP Bushing SHAFT AND BUSHING Using a micrometer and a caliper gauge, measure the oil clear- ance. Standard clearance: 0.021 – 0.043 mm (0.0008 – 0.0017 in.) Front Housing Maximum clearance: 0.07 mm (0.0028 in.) Vane Pump Shaft...
Page 683 SR–24 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring. Inscribed mark: 0, 1, 2, 3, or 4 HINT: There are 5 vane plate lengths corresponding to the following vane pump rotor and cam ring marks:...
Page 684 SR–25 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) INSPECT SPRING Using vernier calipers, measure the free length of the spring. Minimum free length: 35.8 mm (1.409 in.) If it is not within the specification, replace the spring. Vernier Calipers R08702 AVENSIS/CORONA SUP (RM781E)
Page 685 SR–26 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR0VU–08 REPLACEMENT NOTICE: Vinyl Tape When using a vise, do not overtighten it. IF NECESSARY, REPLACE OIL SEAL Using a screwdriver with vinyl tape wound around its tip, remove the oil seal. NOTICE: Be careful not to damage the bushing of the front housing.
Page 686 SR–27 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR0VV–08 REASSEMBLY NOTICE: When using a vise, do not overtighten it. COAT PARTS INDICATED BY ARROWS WITH POWER STEERING FLUID (See page SR–19) INSTALL VANE PUMP SHAFT WITH VANE PUMP PULLEY INSTALL SIDE PLATE Coat 2 new O–rings with power steering fluid, and install them to the side plate.
Page 687 SR–28 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) INSTALL SPRING, FLOW CONTROL VALVE AND PRESSURE PORT UNION Install the spring. Install the flow control valve facing in the correct direction (See page SR–19). Coat a new O–ring with power steering fluid, and install it to the pressure port union.
Page 688 SR–29 STEERING – POWER STEERING VANE PUMP (1AZ–FSE) SR1C9–01 INSTALLATION INSTALL PS VANE PUMP ASSEMBLY Insert the 2 bolts to the PS vane pump assembly. Install the PS vane pump assembly. Tighten the 2 bolts. Torque: 50 N·m (510 kgf·cm, 37 ft·lbf) F13070 INSTALL PRESSURE FEED TUBE Install the pressure feed tube and gasket to the PS vane pump...
Page 690 BODY ELECTRICAL COMBINATION METER ....BE–1 POWER DOOR LOCK CONTROL SYSTEM ....BE–4 DOUBLE LOCKING SYSTEM .
Page 692 BE–1 BODY ELECTRICAL – COMBINATION METER COMBINATION METER BE028–03 CIRCUIT Connector ”A” Connector ”B” I04817 AVENSIS/CORONA SUP (RM781E)
Page 693 BE–2 BODY ELECTRICAL – COMBINATION METER 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 Glow Plug Indicator ABS Warning Low Oil Pressure Warning Check Engine Warning O / D OFF Indicator ECT SNOW Indicator...
Page 694 BE–3 BODY ELECTRICAL – COMBINATION METER Wire Harness Side Ground (Power) Engine ECU (M/T) or Engine and ECT ECU (A/T) Vehicle Speed Sensor Engine ECU (M/T) Engine and ECT ECU (A/T) Ground Outside Temperature Sender Gauge Ground (Fuel) Fuel Sender Gauge Ground (Power) Ground (Speed) Turn Signal Switch (Right)
Page 695 BE–4 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM BE1XO–01 LOCATION Ignition Switch Instrument Panel Junction Block D PWR Fuse D Integration Relay 4 Door Control: Power Window Master Switch D Door Lock Manual Switch Sedan models: LH Door Lock Assembly 2 Door Control:...
Page 696 BE–5 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM Hatchback models: LH Door Lock Assembly D Double Locking Motor D Double Locking Switch RH Door Lock Assembly Wagon models: D Double Locking Motor D Double Locking Switch LH Door Lock Assembly D Double Locking Motor D Double Locking Switch RH Door Lock Assembly...
Page 697 BE–6 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM BE1XP–01 INSPECTION w/ Double locking system: INSPECT DOOR KEY LOCK SWITCH CONTINUITY UNLOCK Switch position Tester connection Specified condition LOCK 5 – 10 Continuity – No continuity LOCK If continuity is not as specified, replace the switch. I19362 w/ Double locking system: INSPECT DOOR UNLOCK DETECTION SWITCH CON-...
Page 698 BE–7 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM Disconnect the leads from terminals. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3, and check that the door lock moves to the LOCK position.
Page 699 BE–8 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM w/ Double locking system: INSPECT PASSENGER’S DOOR PTC THERMISTOR OPERATION UNLOCK Connect the negative (–) lead from the battery to terminal Connect the negative (–) lead from the ammeter to termi- nal 2 and the positive (+) lead to battery positive (+) termi- nal, and check that the current changes from approxi- mately 3.2 A to less than 0.5 A within 20 to 70 seconds.
Page 700 BE–9 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM w/ Double locking system: INSPECT REAR DOOR LOCK MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, and check that the door lock link moves to UNLOCK position.
Page 701 BE–10 BODY ELECTRICAL – POWER DOOR LOCK CONTROL SYSTEM Disconnect the leads from terminals. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. LOCK I19373 AVENSIS/CORONA SUP (RM781E)
Page 702 BE–11 BODY ELECTRICAL – DOUBLE LOCKING SYSTEM DOUBLE LOCKING SYSTEM BE1XQ–01 LOCATION Ignition Switch Instrument Panel Junction Block D PWR Fuse D Integration Relay 4 Door Control: Power Window Master Switch D Door Lock Manual Switch Sedan models: LH Door Lock Assembly 2 Door Control: D Double Locking Motor Power Window Master Switch...
Page 703 BE–12 BODY ELECTRICAL – DOUBLE LOCKING SYSTEM Hatchback models: LH Door Lock Assembly D Double Locking Motor D Double Locking Switch RH Door Lock Assembly Wagon models: D Double Locking Motor D Double Locking Switch LH Door Lock Assembly D Double Locking Motor D Double Locking Switch RH Door Lock Assembly D Double Locking Motor...
Page 704 BE–13 BODY ELECTRICAL – DOUBLE LOCKING SYSTEM BE1XR–01 INSPECTION INSPECT DOUBLE LOCKING SYSTEM FUNCTION HINT: In case of doing the following inspection, must open one of the windows of the doors. To set the double lock, turn the ignition switch OFF, pull out the key, open the driver’s door and then perform the lock operation on the wireless transmitter.
Page 705 BE–14 BODY ELECTRICAL – DOUBLE LOCKING SYSTEM INSPECT PASSENGER’S AND REAR DOUBLE LOCK- ING SWITCH CONTINUITY Switch position Tester connection Specified condition OFF (Double Locking is – No continuity released) ON (Double Locking is 3 – 6 Continuity set) If continuity is not as specified, replace the door lock assembly. INSPECT PASSENGER’S AND REAR DOUBLE LOCK- I19375 ING MOTOR OPERATION...
Page 706 BE–15 BODY ELECTRICAL – DOUBLE LOCKING SYSTEM Connect the wire harness side connector to the double From back side: locking door control relay and inspect the connector from the back side as shown in the chart. I15105 Tester connection Condition Specified condition Driver’s door lock control switch LOCK Below 2.0 V...
Page 707 BE–16 BODY ELECTRICAL – AUDIO SYSTEM AUDIO SYSTEM BE1XS–01 DESCRIPTION RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: Frequency 30 kHz 300 kHz 3 MHz 30 MHz 300 MHz Designation AM (MW) FM (UKW) Radio wave Modulation Amplitube modulation...
Page 708 BE–17 BODY ELECTRICAL – AUDIO SYSTEM Multipath Multipath One type of interference caused by the bounce of radio waves off of obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is re- ceived directly.
Page 709 What is AVC–LAN? AVC–LAN is the abbreviation, which stands for Audio Visual Communication–Local Area Network. This is a unified standard co–developed by 6 audio manufactures associated with Toyota Motor Corpo- ration. The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication and communication signal.
Page 710 BE–19 BODY ELECTRICAL – AUDIO SYSTEM BE1XT–01 TROUBLESHOOTING DISPLAYING RESULTS Results for each check are displayed as follows: GOOD: No DTC is detected for both ”System Check Confirmation” and ”Diagnosis Memory Response”. NCON: The Component does not respond to the ”Diagnosis On Instruction” command. Applicable to only the system where connected components are limited to be used.
Page 711 BE–20 BODY ELECTRICAL – AUDIO SYSTEM FUNCTION HINT: Check the present and past condition of components by performing the System Check and collecting stored DTC memories. Check results shall be displayed as one of six following indications: ”GOOD”, ”ECHN”, ”CHEC” ,”NCON”, ”OLD”...
Page 712 BE–21 BODY ELECTRICAL – AUDIO SYSTEM ”ECHN” Detail Display Mode Screen P160 TUNE UP TUNE DOWN Service Check Mode TUNE UP ECHN TUNE DOWN ch5 (Along) ”ECHN” Detail Display Mode Physical Address of Component P160 TUNE UP TUNE DOWN TUNE UP TUNE DOWN Details for 1st Logical Address...
Page 713 BE–22 BODY ELECTRICAL – AUDIO SYSTEM ”CHEC” Detail Display Mode Screen P190 TUNE UP TUNE DOWN Service Check Mode TUNE UP CHEC TUNE DOWN ch5 (Along) ”CHEC” Detail Display Mode Physical Address of Component P190 TUNE UP TUNE DOWN COde TUNE UP TUNE DOWN Logical Address...
Page 714 BE–23 BODY ELECTRICAL – AUDIO SYSTEM ”OLD” Detail Display Mode Screen P360 TUNE UP TUNE DOWN Service Check Mode TUNE UP TUNE DOWN ch5 (Along) ”CHEC” Detail Display Mode Physical Address of Component P360 TUNE UP TUNE DOWN COde TUNE UP TUNE DOWN Logical Address 1–...
Page 715 BE–24 BODY ELECTRICAL – AUDIO SYSTEM DIAGNOSIS TROUBLE CODE CHART Terms Meaning Three–digit code (shown in hexadecimal) which is given to each component comprising the Physical address AVC – LAN Corresponding to the function, individual symbols are specified.. Two–digit code (shown in hexadecimal) which is given to each function comprising the inner system Logical address of the AVC –...
Page 716 BE–25 BODY ELECTRICAL – AUDIO SYSTEM D Check harness for power supply 01 *4 Slave Reset After engine start, slave component (Communication (Momentary has been disconnected and con- system of component shown by Control) Interruption) nected again. auxiliary code. D Check harness for communica- tion system of component shown by auxiliary code.
Page 717 BE–26 BODY ELECTRICAL – AUDIO SYSTEM Physical address: 190 Radio receiver assembly Countermeasure and Diagnosis content Logical address Diagnosis item inspected parts Replace radio receiver assembly. ROM Error Error is detected in internal ROM. (Communication Control) Replace radio receiver assembly. RAM Error Error is detected in internal RAM.
Page 718 BE–27 BODY ELECTRICAL – AUDIO SYSTEM D Since this DTC is provided for en- Plural Frame Plural frame transmission is (Communication Abort aborted. gineering purpose, it may be de- Control) tected when no actual failure exists. No Disc Inspect CD. Disc cannot be read.
Page 719 BE–28 BODY ELECTRICAL – AUDIO SYSTEM BE1XU–01 LOCATION Steering Switch Multi–display Ignition Switch Instrument Panel Junction Block D RAD & CIG Fuse I18197 AVENSIS/CORONA SUP (RM781E)
Page 720 BE–29 BODY ELECTRICAL – AUDIO SYSTEM BE1XV–01 INSPECTION INSPECT MULTI–DISPLAY CIRCUIT Disconnect the connectors from the multi–display, and inspect the connector on the wire harness side. I12240 Tester connection Condition Specified condition 4 – Ground Constant Continuity Ignition switch ON Battery voltage 7 Ground 7 –...
Page 722 BODY CLIP ........BO–1 SRS AIRBAG .
Page 724 BO–1 BODY – CLIP 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 725 BO–2 BODY – CLIP Shape (Example) Removal/Installation Removal Installation Removal Installation V00012 AVENSIS/CORONA SUP (RM781E)
Page 726 BO19E–01 PRECAUTION The TOYOTA AVENSIS/CORONA is equipped with an SRS (Supplemental Restraint System) such as the driver airbag, front passenger airbag and side airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious acci- dent.
Page 727 BO–4 BODY – FRONT BUMPER FRONT BUMPER BO18F–02 COMPONENTS Headlamp Washer Nozzle RH Clamp Headlamp Washer Hose Clamp Radiator Support Seal Turn Signal Light Headlamp Washer Nozzle LH Turn Signal Light Radiator Grill Support Bracket Upper Bumper Bracket RH Support Bracket Reinforcement 20 (205, 15) Front Bumper Pad...
Page 728 BO–5 BODY – INSTRUMENT PANEL INSTRUMENT PANEL BO19J–03 COMPONENTS w/ Curtain shield air bag: Curtain Shield Airbag Front Pillar Garnish Reinforcement Front Pillar Garnish w/ Curtain shield air bag: No. 1 Brace Front Pillar Garnish Instrument Panel Front Door Opening Trim 18 (185, 13) Rear Door Opening Trim Front Pillar Garnish...
Page 729 BO–6 BODY – INSTRUMENT PANEL Defroster Nozzle No. 2 Side Defroster Duct 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...
Page 730 BO–7 BODY – INSTRUMENT PANEL 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 731 BO–8 BODY – INSTRUMENT PANEL BO3VQ–01 REMOVAL REMOVE FRONT DOOR OPENING TRIMS REMOVE 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 732 BO–9 BODY – INSTRUMENT PANEL REMOVE NO. 1 REGISTER : 4 Clips 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 733 BO–10 BODY – INSTRUMENT PANEL REMOVE CENTER CLUSTER FINISH PANEL : 6 Clips Using a screwdriver, remove the 6 clips of the center clus- ter finish panel. HINT: Tape the screwdriver tip before use. H15310 Remove the center cluster finish panel with holding up as shown in the illustration.
Page 734 BO–11 BODY – INSTRUMENT PANEL BO2J4–02 INSTALLATION INSTALL REINFORCEMENT INSTALL 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) H03666 INSTALL CENTER CLUSTER FINISH PANEL : 6 Clips Install the panel, then connect the connectors.
Page 735 BO–12 BODY – INSTRUMENT PANEL INSTALL NO. 1 UNDER COVER : 3 Clips Install the No. 1 under cover. H16639 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 736 BO–13 BODY – INSTRUMENT PANEL INSTALL STEERING WHEEL (See page SR–6) INSTALL FRONT SEATS Torque: 37 N·m (375 kgf·cm, 27 ft·lbf) INSTALL CENTER PILLAR LOWER COVERS INSTALL REAR DOOR SCUFF PLATES INSTALL REAR DOOR OPENING TRIMS INSTALL COWL SIDE TRIMS INSTALL FRONT DOOR SCUFF PLATES w/ Curtain Shield Airbag: Remove the protection cover.
Page 738 AIR CONDITIONING AIR CONDITIONING SYSTEM ... . AC–1 DRIVE BELT ......AC–2 MANIFOLD GAUGE SET .
Page 740 AC–1 AIR CONDITIONING – AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM AC39E–01 ON–VEHICLE INSPECTION INSPECT IDLE–UP SPEED Warm up engine. Inspect idle–up speed when the these conditions are established. Warm up engine Blower speed control switch at ”HI” position A/C switch ON Temperature control dial at ”COOL”...
Page 741 AC–2 AIR CONDITIONING – DRIVE BELT DRIVE BELT AC2I6–02 ON–VEHICLE INSPECTION INSPECT DRIVE BELT’S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. Correct Wrong CH0086 AVENSIS/CORONA SUP (RM781E)
Page 742 AC–3 AIR CONDITIONING – DRIVE BELT AC39F–01 REMOVAL 1ZZ–FE, 3ZZ–FE Engines: REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt. B00145 1AZ–FSE Engine: REMOVE DRIVE BELT Using the SST, loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt.
Page 743 AC–4 AIR CONDITIONING – DRIVE BELT AC39G–01 INSTALLATION 1ZZ–FE, 3ZZ–FE Engines: INSTALL DRIVE BELT Turning the drive belt tensioner arm clockwise, and install the drive belt. B00145 1AZ–FSE Engine: REMOVE DRIVE BELT Using the SST, turning the drive belt tensioner arm clockwise, and install the drive belt.
Page 744 AC–5 AIR CONDITIONING – MANIFOLD GAUGE SET MANIFOLD GAUGE SET AC2A7–03 SET ON 1ZZ–FE, 3ZZ–FE, 1AZ–FSE Engines LHD: RHD: : Low Pressure Charging Hose : High Pressure Charging Hose I18808 CONNECT CHARGE HOSE TO MANIFOLD GAUGE Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses.
Page 745 AC–6 AIR CONDITIONING – MANIFOLD GAUGE SET CONNECT QUICK DISCONNECT ADAPTER TO SER- VICE VALVES HINT: Push the quick disconnect adapter onto the service valve, slide, Sleeve then slide the sleeve of the quick disconnect adapter downward to lock it. N04392 AVENSIS/CORONA SUP (RM781E)
Page 746 AC–7 AIR CONDITIONING – MANIFOLD GAUGE SET AC2A8–02 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. N06553 INSTALL CAPS TO SERVICE VALVES ON REFRIGER- ANT LINE...
Page 747 AC–8 AIR CONDITIONING – REFRIGERANT LINE REFRIGERANT LINE AC2IB–01 ON–VEHICLE INSPECTION INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. AVENSIS/CORONA SUP (RM781E)
Page 748 AC–9 AIR CONDITIONING – REFRIGERANT LINE AC2IC–02 LOCATION 1ZZ–FE, 3ZZ–FE, 1AZ–FSE Engines LHD models: Piping Clamp Suction Hose 10 (100, 7) 5.5 (55, 48 in.·lbf) Liquid Tube 10 (100, 7) 10 (100, 7) Compressor Discharge Hose Condenser Liquid Tube RHD models: Piping Clamp Suction Hose 10 (100, 7)
Page 749 AC–10 AIR CONDITIONING – REFRIGERANT LINE AC2ID–02 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. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torqued. Part tightened N·m kgf·cm...
Page 750 AC–11 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH AC1GA–05 ON–VEHICLE INSPECTION INSPECT COMPRESSOR FOR METALLIC SOUND Check there is abnormal metallic sound from the compressor when the A/C switch is ON. If abnormal metallic sound is heard, replace the compressor as- sembly.
Page 751 AC–12 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC1GB–03 COMPONENTS Suction Hose 1ZZ–FE, 3ZZ–FE Engines: 10 (100, 7) Compressor Discharge Hose z O–Ring 25 (250, 18) Drive Belt Engine Under Cover RH 10 (100, 7) 1AZ–FSE Engine: Suction Hose z O–Ring Discharge Hose z O–Ring Compressor...
Page 752 AC–13 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC2IP–02 REMOVAL RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REMOVE ENGINE UNDER COVER RH REMOVE DRIVE BELT (See page AC–3) DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses.
Page 753 AC–14 AIR CONDITIONING – COMPRESSOR AND MAGNETIC CLUTCH AC39H–01 INSTALLATION 1ZZ–FE, 3ZZ–FE Engines: INSTALL COMPRESSOR Install the compressor with 3 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the connector. I13000 1AZ–FSE Engine: INSTALL COMPRESSOR Install the compressor with 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf) Connect the connector.
Page 754 AC–15 AIR CONDITIONING – AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR AC39I–01 COMPONENTS Blower Unit Air Duct Engine (and ECT) ECU Cowl Side Trim Lower Finish Panel Front Door Scuff Plate No. 2 Under Cover Blower Unit Case Air Inlet Servomotor I18810 AVENSIS/CORONA SUP (RM781E)
Page 755 AC–16 AIR CONDITIONING – AIR INLET SERVOMOTOR AC39J–01 REMOVAL REMOVE FRONT DOOR SCUFF PLATE ON PAS- SENGER SIDE REMOVE COWL SIDE TRIM ON PASSENGER SIDE REMOVE NO. 2 UNDER COVER REMOVE LOWER FINISH PANEL (See page BO–8) REMOVE ENGINE (and ECT) ECU RHD Models Only: REMOVE THEFT DETERRENT ECU Disconnect the connector.
Page 756 AC–17 AIR CONDITIONING – AIR INLET SERVOMOTOR AC39K–01 INSPECTION ”REC” LHD: INSPECT AIR INLET SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 7 and negative (–) lead to terminal 1 and check that arm turns to ”REC” side smoothly. If operation is not as specified, replace the servomotor.
Page 757 AC–18 AIR CONDITIONING – AIR INLET SERVOMOTOR AC39L–01 INSTALLATION Installation is in the reverse order of removal (See page AC–16). AVENSIS/CORONA SUP (RM781E)
Page 758 AC–19 AIR CONDITIONING – AIR MIX SERVOMOTOR AIR MIX SERVOMOTOR AC39M–01 REMOVAL REMOVE BLOWER UNIT (See page AC–16) REMOVE AIR MIX SERVOMOTOR Disconnect the connector. Remove the 3 screws and air mix servomotor. I19340 AVENSIS/CORONA SUP (RM781E)
Page 759 AC–20 AIR CONDITIONING – AIR MIX SERVOMOTOR AC39N–01 INSPECTION LHD: INSPECT AIR MIX SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 6 and the negative (–) lead to terminal 7 and check that the arm turns to ”WARM” side smoothly. ”WARM”...
Page 760 AC–21 AIR CONDITIONING – AIR MIX SERVOMOTOR RHD: INSPECT AIR MIX SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 6 and the negative (–) lead to terminal 7 and check that the arm turns to ”COOL” side smoothly. If operation is not as specified, replace the servomotor.
Page 761 AC–22 AIR CONDITIONING – AIR MIX SERVOMOTOR AC39O–01 INSTALLATION Installation is in the reverse order of removal (See page AC–19). AVENSIS/CORONA SUP (RM781E)
Page 762 AC–23 AIR CONDITIONING – AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AC39P–01 REMOVAL REMOVE AIR OUTLET SERVOMOTOR Disconnect the connector. Remove the 3 screws and air outlet servomotor. I19341 AVENSIS/CORONA SUP (RM781E)
Page 763 AC–24 AIR CONDITIONING – AIR OUTLET SERVOMOTOR AC39Q–01 INSPECTION ”DEF” LHD: INSPECT AIR OUTLET SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 4 and negative (–) lead to terminal 5 and check that arm turns to ”DEF” side smoothly. If operation is not as specified, replace the servomotor.
Page 764 AC–25 AIR CONDITIONING – AIR OUTLET SERVOMOTOR RHD: ”DEF” INSPECT AIR OUTLET SERVOMOTOR OPERATION Connect the positive (+) lead from the battery to terminal 5 and negative (–) lead to terminal 4 and check that arm turns to ”DEF” side smoothly. If operation is not as specified, replace the servomotor.
Page 765 AC–26 AIR CONDITIONING – AIR OUTLET SERVOMOTOR AC39R–01 INSTALLATION Installation is in the reverse order of removal (See page AC–23). AVENSIS/CORONA SUP (RM781E)
Page 766 AC–27 AIR CONDITIONING – AIR CONDITIONER CONTROL ASSEMBLY AIR CONDITIONER CONTROL ASSEMBLY AC39S–01 COMPONENTS Center Cluster Finish Panel Bulb A/C Control Assembly I18087 AVENSIS/CORONA SUP (RM781E)
Page 767 AC–28 AIR CONDITIONING – AIR CONDITIONER CONTROL ASSEMBLY AC39T–01 REMOVAL : 6 Clips REMOVE CENTER CLUSTER FINISH PANEL Using a screwdriver, remove the cluster finish panel. H15310 Remove the cluster finish panel shown in the illustration. Disconnect the connecters. H16288 REMOVE A/C CONTROL ASSEMBLY Remove the 4 screws and A/C control panel assembly.
Page 768 AC–29 AIR CONDITIONING – AIR CONDITIONER CONTROL ASSEMBLY AC39U–01 INSTALLATION INSTALL A/C CONTROL ASSEMBLY Install the A/C control panel assembly to the cluster finish panel with the 4 screws. INSTALL CENTER CLUSTER FINISH PANEL : 6 Clips Connect the connectors. Install the cluster finish panel.
Page 769 AC–30 AIR CONDITIONING – AIR CONDITIONER AMPLIFIER AIR CONDITIONER AMPLIFIER AC39V–01 ON–VEHICLE INSPECTION REMOVE A/C CONTROL ASSEMBRY (See page AC–28) INSPECT A/C AMPLIFIER CIRCUIT From back side: I18812 Tester connection Condition Specified condition IG ON. Ambient temp.: 25 °C (77 °F) 1.35 –...
Page 770 AC–31 AIR CONDITIONING – AIR CONDITIONER AMPLIFIER IG ON. Set temp.: Except MAX. COOL Below 1.0 V AMC ↔ GND (A15 10 ↔ A14 12) AMC ↔ GND (A15–10 ↔ A14–12) IG ON. Set temp.: COOL 10 – 14 V IG ON.
Page 772 ID–1 ALPHABETICAL INDEX...
Page 773 ID–2 ALPHABETICAL INDEX (A – F) Page CLUTCH UNIT ........CL–9 COMBINATION METER .
Page 774 ID–3 ALPHABETICAL INDEX (G – R) Page Page GENERAL INFORMATION NEUTRAL START SWITCH (A246E) ....AX–3 (HOW TO TROUBLESHOOT ECU NEUTRAL START SWITCH (U240E) ....AX–6 CONTROLLED SYSTEMS) .
Page 775 ID–4 ALPHABETICAL INDEX (S – V) Page SHIFT AND SELECT LEVER SHAFT (C50, C250) ..MX–37 SHIFT AND SELECT LEVER SHAFT (E351) ..MX–37 SHIFT AND SELECT LEVER SHAFT (S54, S55) .

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Corona 2000 Avensis 2001 Corona 2001 Avensis 2002 Corona 2002

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