Verkstadshandbok Corolla

toyota :: Toyota Corolla Wagon L4-96.
8 1587cc
1.6L DOHC (4A-FE) (1996)
> Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations
Door Lock Relay: Locations

J/B No.1 Left Kick Panel (Fig 20)
> Relays and Modules > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 7
Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

J/B No.2 Engine Compartment Left (Fig 22)

J/B No.4 Right Kick Panel (Fig 26)
R/B No.5 Engine Compartment Left (Fig 27)

R/B No.6 Engine Compartment Front Right (Canada) (Fig 27)
Details
Engine Compartment (Fig 18)

Instrument Panel (Fig 18)
Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations
Sunroof / Moonroof Relay: Locations

> Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 15



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Testing and Inspection
> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 28



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations
Blower Motor Relay: Locations

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 37



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations
Compressor Clutch Relay: Locations

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 45



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations
Condenser Fan Motor Relay: Locations

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 53



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Testing and Inspection
Control Module HVAC: Testing and Inspection

ON-VEHICLE INSPECTION
Inspect A/C Amplifier Circuit
1. Disconnect the connector from the amplifier and inspect connector on wire harness side, as shown in the chart.
TestON Ignition switch

conditions:-
- Temperature control lever to MAX COOL
- ONBlower switch
If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the ci
2. Connect the connector to amplifier and inspect the wire harness side connector from the back side, as shown in the

conditions:-
- Blower switch HI
- ONA/C switch
- Install manifold gauge set
> Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Testing and Inspection > Page 61
Control Module HVAC: Service and Repair
AMPLIFIER REMOVAL
1. Remove Glove Compartment Parts
2. Remove Amplifier
a. Disconnect the connector.b. Remove the screw and the amplifier.
AMPLIFIER INSTALLATION
Installation is in the reverse order of removal.
> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations
Daytime Running Lamp Relay: Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 66



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations
Headlamp Relay: Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 74



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations
Horn Relay: Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 82



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations
Tail Lamp Relay: Locations

> Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 90



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 99



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations
Relay Box: Locations

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 107



Details

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Loca
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Loca
117
Engine Control Module: Connector Locations

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component
Information > Locations > Component Locations > Page 118

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diag
Instructions
Engine Control Module: Diagram Information and Instructions
How To Read Ground Points

Ground Points
The Ground Point circuit diagram shows the connection from all major parts to the respective ground points. When trou
How to Read Power Source
Information > Diagrams > Diagram Information and Instructions > Page 121

Power Source (Current Flow Chart)
Power Source
The chart shows the route by which current flows from the battery to each electric source (Fusible Link, Circuit Breake
Key to Diagrams

Power Window
A: System TitleB: Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish
Example: 1 Indicates Relay Block No. 1.
C: Indicates the connector to be connected to a part (the numeral indicates the pin No.)
Explanation of pin use.

Connector
The pins shown are only for the highest grade, or only include those in the specification.
D: Connector Color
Connectors not indicated are milky white in color.
E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, Engine type, or specification is
are pin numbers.
Wiring Harness Connector
The first letter of the code for each wiring harness and wiring harness connector(as indicates the component's loc
When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, lH2) this in
H: Represent a part (all parts are shown in sky blue). The code is the same as the code used in parts position
I: Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Block
them from other parts (different junction blocks are shaded differently for further clarification).
Example:
Junction Block
J : Indicates the wiring color.

Wire colors are indicated by an alphabetical code.
B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
of the = Pink R = RedV =

Wiring Color
K: Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for Bod
Example:
Splice Point
The Location of Splice Point I 5 is indicated by the shaded section
L: Page No.M: Indicates a shielded cable
Shielded Cable
N: Indicates a ground point
The first letter of the code for each ground point(S) indicates the component's location, e.g, "E" for the Engine Co
O: Indicates the pin number of the connector.
The numbering system is different for female and male connectors.
Pin Number Of The Connector
P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is sho
Instructions > Page 125
Engine Control Module: Diagnostic Aids
Disconnection of Male and Female Connectors
Disconnection Of Male And Female Connectors
To pull apart the connectors, pull on the connector itself, not the wire harness.
HINT: Check to see what kind of connector you are disconnecting before pulling apart.

Glossary Of Terms And Symbols (Part 1 Of 2)

How to Replace Terminals

Special Tool
With terminal retainer or secondary locking device
1. Prepare The Special Tool
HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown
2. Disconnect Connector
Secondary Locking Device Or Terminal Retainer
3. Disengage The Secondary Locking Device Or Terminal Retainer.
a. Locking device must be disengaged before the terminal locking clip can be released and the terminal removed
NOTE: Do not remove the terminal retainer from connector body.

Non-Waterproof Type Connector
A - For Non-Waterproof Type Connector

HINT:
The needle insertion position varies according to the connector's shape (number of terminals etc.), so check th
"Case 1"
Raise the terminal retainer up to the temporary lock position.
"Case 2"
Open the secondary locking device.
Waterproof Type Connector
B - For Waterproof Type Connector
HINT: Terminal retainer color is different according to connector body.

Example:Terminal Retainer
: Connector Body
Black or White : Gray
Black or White : Dark Gray
Gray or White : Black

"Case 1"
Type where terminal retainer is pulled up to the temporary lock position (Pull Type)
Insert the special tool into the terminal retainer access hole and pull the terminal retainer up to the tempora
HINT:
The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check
"Case 2"
Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal r

Terminal Retainer
Push the terminal retainer down to the temporary lock position.
Locking Lug
c. Release the locking lug from terminal and pull the terminal out from rear.
Installation Of Terminal To Connector
4. Install Terminal To Connector

a. Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.2. Insert the terminal until the locking lug locks firmly.3. Insert

Secondary Locking Device
b. Push the secondary locking device or terminal retainer in to the full lock position.
5. Connect Connector
Continuity and Resistance Check
Continuity And Resistance Check
a. Disconnect the battery terminal or wire so there is no voltage between the check points.b. Contact the two leads of
If the circuit has diodes, reverse the two leads and check again.When contacting the negative lead to the diode positiv

10 k/V c. Use a Volt/Ohm meter with high impedance (minimum) for troubleshooting of the electrical circuit.
Finding A Short Circuit

ONa. Remove the blown fuse and disconnect all loads of the fuse.B. Connect a test light in place of the fuse.c. Estab
d. Disconnect and reconnect the connectors while watching the test light.
The short lies between the connector where the test light stays lit and the connector where the light goes out.
e. Find the exact location of the short by lightly shaking the problem wire along the body.
CAUTION:
a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, t
static electricity.)
B. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your bod
with the terminals of leads from the IC, etc. of the replacement part (spare part).
Voltage Check
ON
ON ON OFFExample:A- Ignition SW B- Ignition SW and SW 1 C- Ignition SW, SW 1 and Relay (Connect the

Voltage Check
a. Establish conditions in which voltage is present at the check point.
ON
ON ON OFFExample:A. Ignition SW B. Ignition SW and SW 1 C. Ignition SW, SW 1 and Relay (SW 2 )
b. Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive
component terminal. This check can be done with a test a light instead of a voltmeter.
Engine Control Module: Connector Views


> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Test
Pinout Values
Engine Control Module: Testing and InspectionControl Module Pinout Values

Information > Testing and Inspection > Control Module Pinout Values > Page 139

Pinout Values > Page 140
Engine Control Module: Testing and InspectionECM Power Source Circuit

ECM Power Source Circuit
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the E
WIRING DIAGRAM

INSPECTION PROCEDURE
Engine Control Module: Service and Repair
ENGINE CONTROL MODULE (ECM) ECM INSPECTION
1. REMOVE FLOOR MAT BRACKET2. REMOVE ECM
(a) Disconnect the 3 connectors from the ECM.(b) Remove the ECM.
3. INSPECT ECM4. REINSTALL ECM
(a) Install the ECM.(b) Connect the 3 connectors to the ECM.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System
Locations
EFI Main Relay: Locations

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (
Computer/Fuel System)] > Component Information > Locations > Page 146



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System
Locations > Page 151
EFI Main Relay: Testing and Inspection

EFI MAIN RELAY INSPECTION
1. REMOVE EFI MAIN RELAY
2. INSPECT EFI MAIN RELAY (NIPPONDENSO)A. Inspect relay continuity

- Using an ohmmeter, check that there is continuity between terminals 1 and 2.
- If there is no continuity, replace the relay.
- Check that there is no continuity between terminals 3 and 5.
- If there is continuity, replace the relay.
B. Inspect relay operation

- Apply battery voltage across terminals 1 and 2.
3. INSPECT EFI MAIN RELAY (BOSCH)A. Inspect relay continuity

4. REINSTALL EFI MAIN RELAY
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel Pump Relay] > Compon
Inspection
Circuit Opening Relay: Testing and Inspection

CIRCUIT OPENING RELAY INSPECTION
1. REMOVE CENTER CLUSTER FINISH LOWER PANEL2. REMOVE FINISH LOWER CENTER PANEL3. R
4. REINSTALL EFI MAIN RELAYA. Inspect relay continuity

- Using an ohmmeter, check that there is continuity between terminals STA and E1.
- Check that there is continuity between terminals +B and FC.
- Check that there is no continuity between terminals +B and FP.

- Apply battery voltage across terminals STA and E1.
- Using an ohmmeter, check that there is continuity between terminals +B and FP.
- Apply battery voltage across terminals +B and FC.
- Check that there is continuity between terminals +B and FP.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel Pump
Relay] > Component Information > Testing and Inspection > Page 157

5. REINSTALL CIRCUIT OPENING RELAY6. REINSTALL FINISH LOWER CENTER PANEL7. INSTALL CE
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System
Locations

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System




> Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - OC
Seat Occupant Classification Module - Air Bag: Technical Service BulletinsRestraints - OCS System Initializatio
COLLISION REPAIR INFORMATIONFOR THE COLLISION REPAIR PROFESSIONAL
TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION
SECTION: ELECTRICAL BULLETIN # 177
MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS
DATE: MARCH 2010
Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or d
If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are servic
NOTE:
It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SR
Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Spe
Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to
^ The OCS Electronic Control Unit (ECU) is replaced
^ Accessories such as a seatback tray are installed on the passenger seat
^ The passenger seat is removed and replaced or reinstalled
^ The vehicle is involved in an accident or collision
Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.c
> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations
Starter Relay: Locations

> Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 177



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Testing and Inspectio
Shift Interlock Control Module: Testing and Inspection
Fig. 9 Shift Lock ECU Connector Terminals.

> Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information >
Testing and Inspection > Page 187

Fig. 13 Shift Lock Control ECU Inspection.




Figs. 9 through 12. Figs. 13 through 17
Using a suitable voltmeter, measure voltage at each ECU connector terminal, . Refer to for measuringconditions and v
> Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations
Rear Defogger Relay: Locations

> Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 194



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Inform
Information and Instructions
Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) >
Component Information > Diagrams > Diagram Information and Instructions > Page 206

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Information and Instructions > Page 210
Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Coolant Temperature Sensor/Switch (For Computer): Description and Operation

CIRCUIT DESCRIPTION
A thermistor built into the engine coolant temperature sensor changes the resistance value according to the engine
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection

ECT SENSOR INSPECTION
1. DRAIN ENGINE COOLANT2. REMOVE ECT SENSOR
3. INSPECT ECT SENSOR RESISTANCE

- Using an ohmmeter, measure the resistance between the terminals.
Resistance: Refer to the graph
- If the resistance is not as specified, replace the ECT sensor.

4. REINSTALL ECT SENSOR
- Install a new gasket to the ECT sensor.
5. FILL RADIATOR WITH ENGINE COOLANT
> Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Inform
> Sensors and Switches > Sensors and Switches - HVAC > System Information > Technical Service Bulletins > A/C - Sensor Inspection Procedures
Sensors and Switches - HVAC: Technical Service BulletinsA/C - Sensor Inspection Procedures
HEATING & AIR CONDITIONINGAC009-04
Title:SENSOR INSPECTION FOR AIRCONDITIONING SYSTEM
Models'89 - Current All Models
December 16, 2004
Introduction
This service bulletin contains inspection procedures to more precisely confirm proper operation of the following tempe
^ Room Temperature Sensor
^ Ambient Temperature Sensor
^ Air Duct Sensor
^ Evaporator Temperature Sensor
^ Solar Sensor Room Humidity Sensor
Applicable Vehicles
All 1989 - Current model year Toyota vehicles.
Warranty Information
Inspection Procedure
1. Inspect Room Temperature Sensor.

> Sensors and Switches > Sensors and Switches - HVAC > System Information > Technical Service Bulletins > A/C - Sensor Inspection Procedures > Page 230

A. Measure the sensor resistance.
NOTE:
^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor.
^ When measuring, the sensor temperature must be the same as the ambient temperature.
HINT:
As the temperature increases, the resistance decreases.
2. Inspect Ambient Temperature Sensor.
A. Measure the sensor resistance according to the selected graph (specification).
NOTE:

HINT:
3. Inspect Air Duct Sensor.
A. Measure the sensor resistance according to the table and graph (specification).
NOTE:
HINT:
4. Inspect Evaporator Temperature Sensor.


Select the appropriate graph (specification) using the table.
NOTE:
Please inspect the sensors for model years not indicated by this bulletin, according to the instructions in the applicab


NOTE:
^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the se
HINT:
5. Inspect Solar Sensor.

Four types of solar sensors are used on Toyota vehicles depending on the vehicle specifications. The inspection p
Procedure A:

a. Disconnect the solar sensor connector.
b. Measure the resistance between terminals 1 and 2 of the solar sensor under the following conditions:
^ Cover the sensor with a cloth to avoid direct light.
^ Expose the sensor to light from a distance of 300 mm (11.81 in.) or less with an inspection light.
NOTE:
^
Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, c
HINT:
If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
Standard:
Procedure B:

NOTE:
When using an analog tester, connect the positive (+) lead to terminal 3 and negative (-) lead to terminal 2 of
HINT:
Standard:
Procedure C:
a. Turn the ignition switch ON.
b. Measure the voltage between terminals TSR (+) and CLTE (-) of the connector under the following conditi
HINT:
^ If the light is weak, the sensor may not react. Be sure to use an incandescent light for an inspection light.
^ Do not disconnect the solar sensor connector.

Standard:

c. Measure the voltage between terminals TSL (+) and CLTE (-) of the connector under the following conditi
HINT:
Standard:
Procedure D:

b. Using the tester, measure the voltage between terminals TSD (+) and CLTE (-) of the connector under the f
HINT:

Standard:
6. Inspect Room Humidity Sensor.
Measure the humidity and output voltage of the humidity sensor when the sensor is installed on the vehicle and th
HINT:
For the inspection procedure of the room temperature sensor, refer to "Room Temperature Sensor Inspection Proced
A. Turn the ignition switch to the ON position.
B. Measure the voltage between terminal VO (3) and GND (2) of the room humidity sensor.
C.
Measure the humidity and voltage when the room temperature (humidity sensor position) is 77F (25C). Acc
> Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Instruments - Turn Signal Operation Im
Turn Signal Switch: Technical Service BulletinsInstruments - Turn Signal Operation Improved
ELECTRICALEL004-97
April 25, 1997
Title: TURN SIGNAL OPERATION: HAZARD SWITCH
Models:'93-'96 Corolla (NAP)
Introduction: A production change has been made to the hazard switch to improve the performance of the turn signal in
Production Change Information
V.I.N. PLANT
INX** ## E # TZ497237 NUMMI
2T1BA02E3VC158201 TMMC
2T1BB02E7VC178500 TMMC
Parts Information
^ Two of the three part numbers for the current supply parts were not changed.
^
Countermeasure switches can be identified by the production code mark located on the switch housing. Parts produ
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information >
and Instructions
Camshaft Position Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
and Instructions > Page 255
Camshaft Position Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Camshaft Position Sensor: Description and Operation

CIRCUIT DESCRIPTION
Camshaft position sensor (G signal) consist of a signal plate and pickup coil.The 5 signal plate has one tooth on i
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) >
> Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (
For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 271

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Diagram Information and Instructions > Page 275



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Page 286

CIRCUIT DESCRIPTION
> Page 287



> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Pos
Information > Specifications > Electrical Specifications
Engine RPM Sensor (NE signal): Electrical Specifications

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
Information > Specifications > Electrical Specifications > Page 292
Engine RPM Sensor (NE signal): Mechanical Specifications

Torque ..................................................................................................................................................................................
Information > Diagrams > Diagram Information and Instructions
Engine RPM Sensor (NE signal): Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [
Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 295

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Engine RPM Sensor (NE signal): Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Information > Diagrams > Page 310
Engine RPM Sensor (NE signal): Description and Operation

CIRCUIT DESCRIPTION
Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil.The NE signal plate has 34 teeth
Engine RPM Sensor (NE signal): Testing and Inspection

CRANKSHAFT POSITION SENSOR INSPECTION
NOTICE: "Cold" and "Hot" in the following sentences express the temperature of the sensor itself."Cold" is fr
1. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR
2. INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE

- If the resistance is not as specified replace the crankshaft position sensor.

3. RECONNECT CRANKSHAFT POSITION SENSOR CONNECTOR
Engine RPM Sensor (NE signal): Service and Repair
CRANKSHAFT POSITION SENSOR REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR2. REMOVE CRANKSHAFT POSITION

- Remove the bolt and crankshaft position sensor.
Torque: 9.3 N.m (95 kgf.cm, 82 in.lbf)
CRANKSHAFT POSITION SENSOR INSTALLATION
INSTALLATION HINT: Installation is in the reverse order of removal.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Informa
Intake Air Temperature Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Intake Air Temperature Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Intake Air Temperature Sensor: Description and Operation
CIRCUIT DESCRIPTION
The intake air temp. sensor is built into the air cleaner cap and senses the intake air temperature.A thermistor buil
Intake Air Temperature Sensor: Testing and Inspection
IAT SENSOR INSPECTION
1. REMOVE IAT SENSOR2. INSPECT IAT SENSOR RESISTANCE

- If the resistance is not as specified, replace the IAT sensor.

3. REINSTALL IAT SENSOR
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Info
Manifold Pressure/Vacuum Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Manifold Pressure/Vacuum Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Manifold Pressure/Vacuum Sensor: Description and Operation
CIRCUIT DESCRIPTION
By a built-in sensor unit, the manifold absolute pressure sensor detects the intake manifold pressure as voltage. T
Manifold Pressure/Vacuum Sensor: Testing and Inspection
MAP SENSOR INSPECTION

1. INSPECT POWER SOURCE VOLTAGE OF MAP SENSOR
- Disconnect the MAP sensor connector.
- Turn the ignition switch ON.
- Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
- Turn the ignition switch OFF.

- Reconnect the MAP sensor connector.
2. INSPECT POWER OUTPUT OF MAP SENSOR
- Disconnect the vacuum hose on the air intake chamber side.
- Connect a voltmeter to terminals PIM and E2 of the ECM, and measure the output voltage under ambient atm
- Apply vacuum to the MAP sensor in 13.3 kPa (100 mm Hg, 3.94 in. Hg) segments to 66.7 kpa (500 mmHg, 1
- Measure the voltage drop from step (c) above for each segment.
Voltage drop:
- Reconnect the vacuum hose to the MAP sensor.

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technica
Bank 1/Bank 2 O2 Sensor identification
Oxygen Sensor: Technical Service BulletinsEngine Controls - Bank 1/Bank 2 O2 Sensor identification
ENGINEEG034-07
Title:ENGINE BANK 1 AND BANK 2 A/F ANDO2 IDENTIFICATION
Models:'93 - '08 Applicable Models
June 28, 2007
The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should
Introduction
This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A
This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2
^ Bank 1 (B1) refers to the bank that includes cylinder No. 1.
^ Bank 2 (B2) refers to the bank opposite bank 1.
^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters.
^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters.
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component
Information > Technical Service Bulletins > Engine Controls - Bank 1/Bank 2 O2 Sensor identification > Page 359

Applicable Vehicles


Engine Bank Identification

A/F and 02 Sensor Identification
Bank 1/Bank 2 O2 Sensor identification > Page 363
Oxygen Sensor: Technical Service BulletinsEngine Controls - O2 Sensor Monitor Threshold Values
SPECIAL SERVICE TOOLSSS002-03
December 17, 2003
TitleO2S TEST RESULTS (MODE 05)
ModelsAll '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB
Introduction
This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and so
All 1996Vehicles^
Applicable - 2003 model year Toyota vehicles.
^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles.
^ 2004 model year Scion xA and xB vehicles.
Function Description
Checking O2S Test Results
To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key
The process for checking 02S test results is described in the following three basic steps:
1. Completing the O2S Readiness Monitor.

2. Accessing O2S Test Results.
3. Comparing O2S Test Results to Failure Thresholds.
Required SSTs
Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933
NOTE:
Completing O2S Readiness Monitor
1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester.

2. Start the engine.
3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor.
HINT:
The 02S Monitor is completed when the following conditions are met:
^ Two (2) minutes or more passed after the engine start.
^ The Engine Coolant Temperature (ECT) is 167F (75C) or more.
^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes.
^ Vehicle is in closed loop.
^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor).
A. Allow the engine to idle for two minutes.
B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167F (75C).
C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds.
D. Stop the vehicle and allow the engine to idle for more than 20 seconds.
E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.)
In addition, perform the following steps for the Rear O2S Readiness Monitor:
A. Select second gear.
B. Allow the vehicle to run at 30 mph (48 km/h) or more.
C. Keep the accelerator pedal "off-idle" for more than 10 seconds.
D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake
E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h).
F. Repeat steps B - E at least twice in one driving cycle.
Accessing O2S Test Results
1. On the Diagnostic Tester* screen, select the following menus:
^ DIAGNOSTICS
^ CARB OBD II

^ O2S TEST RESULTS
A list of the available oxygen sensors will be displayed.
2. Select the desired oxygen sensor and press Enter.
NOTE:
The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor
3. Compare the test results with the values listed in the Failure Threshold Chart.
* Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a g
Comparing O2S Test Results to Failure Thresholds
1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table,"
2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart.
3.
Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S te
Example:

A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration).
B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for
C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B."
17 x 0.3906 = 6.6%
D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal.
NOTE:
^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean.
^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich.
^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean.
^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich.
NOTE:
Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays t





O2S Application Table
O2S Failure Threshold Charts


CHART 1

CHART 2
CHART 3
CHART 4

CHART 5
CHART 6

CHART 7

CHART 8
CHART 9

CHART 10

CHART 11

CHART 12
CHART 13

CHART 14

CHART 15

CHART 16
CHART 17

CHART 18
CHART 19

CHART 20


CHART 21

CHART 22


CHART 23


CHART 24

CHART 25


CHART 26


CHART 27


CHART 28

CHART 29

CHART 30
Oxygen Sensor: Specifications
Tightening torque 33 ft.lb

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagram
Instructions
Oxygen Sensor: Diagram Information and Instructions

Ground Points

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Oxygen Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Oxygen Sensor: Description and Operation
CIRCUIT DESCRIPTION
To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic
Oxygen Sensor: Testing and Inspection
HEATED OXYGEN SENSOR INSPECTION

1. INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSOR
- Using an ohmmeter, measure the resistance between the terminals +B and HT.
Resistance: At 20 C (68 F): 11 - 16 ohm
- If the resistance is not as specified, replace the heated oxygen sensor.
Torque: 44N m (45O kgf.cm, 33 ft.lbf)

> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information >
Instructions
Throttle Position Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Throttle Position Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Throttle Position Sensor: Description and Operation

CIRCUIT DESCRIPTION
The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Compon
Diagram Information and Instructions
Transmission Position Switch/Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor,
A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 446

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Diagram Information and Instructions > Page 450
Transmission Position Switch/Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
461
Transmission Position Switch/Sensor: Description and Operation

CIRCUIT DESCRIPTION
The ECM determines the ignition timing, turns on Tr1 at a predetermined angle ( CA) before the desired ignition
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Sp
Vehicle Speed Sensor: Specifications

Torque ..................................................................................................................................................................................
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Di
Vehicle Speed Sensor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information >
Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Di

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information >
Diagrams > Diagram Information and Instructions > Page 507

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Page 511



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Page 521
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Pa

CIRCUIT DESCRIPTION
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > C
Specifications > Electrical Specifications

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
Specifications > Electrical Specifications > Page 527

Torque ..................................................................................................................................................................................

Ground Points
> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft
Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 530

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Page 545

CIRCUIT DESCRIPTION
Page 546



Page 547


> Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair
Ignition Switch: Service and Repair
1. On models equipped with airbags, Technician Safety Information. disarm airbag system as outlined under
2. On models less airbags, disconnect battery ground cable.
3. On models with coded audio anti-theft systems,
remove steering wheel, if necessary, steering column garnish, if equipped, upper and lowercovers.
4. Disconnect electrical connectors from ignition switch.
5. Turn ignition key to ACC position. Push down the stop pin with a screwdriver and pull out ignition key cylinder.
6. Technician Safety Information
On models with air bagsystem, Technician Safety Information.Reverse procedure to install. If audio system w
> Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - OCS System Initialization
Seat Occupant Sensor: Technical Service BulletinsRestraints - OCS System Initialization
DATE: MARCH 2010
NOTE:
> Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Testing and Inspection
Shift Interlock Switch: Testing and Inspection
Fig. 18 Shift Lock Control Switch Connector.

Fig. 20 Shift Lock Control Switch Inspection.
Figs. 18 through 20.Using a suitable ohmmeter, check for continuity at terminals as shown in
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagra
Instructions

Ground Points
> Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins fo
> Jul > 97 > Windows - Power Window Switch Inoperative
Power Window Switch: All Technical Service BulletinsWindows - Power Window Switch Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
POWER WINDOW SWITCH INOPERATIVE
Models:
'93 - '97 TMMC Corolla
Introduction The front passenger side power window switch (P/N 84810-12080) may not operate due to lubrication fro
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
Replace the Power Window Switch, part number 84810-12080.
NOTE:
The lubrication used on the wire harness dries shortly after assembly preventing any further contamination of the w
Applicable Warranty:
This repair Is covered under the Toyota Comprehensive Warranty which Is In effect for 36 months or 36,000 miles, wh
> Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Wind
Windows - Power Window Switch Inoperative
Power Window Switch: Customer InterestWindows - Power Window Switch Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
Models:
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
NOTE:
> Maintenance > Alignment > System Information > Technical Service Bulletins > Alignment - Camber Adjusting Bolts
Alignment: Technical Service BulletinsAlignment - Camber Adjusting Bolts

REF.: SUSPENSION
NO.: SU0O4-96
DATE: JULY 12, 1996
MODEL: TER, PAS, COR, CAM,
AVL, CEL, PRV
CAMBER ADJUSTING BOLTS
To increase camber adjusting capability, the steering knuckle set bolts can be replaced with new camber adjusting bolts
NOTE:
Vehicles which are out of alignment specifications due to a collision or worn out parts, should be inspected for dam
To change camber, install the adjusting bolt in the lower steering knuckle mounting hole. If a camber change greater th
> Maintenance > Alignment > System Information > Technical Service Bulletins > Alignment - Camber Adjusting Bolts > Page 604

CAMBER ADJUSTING BOLTS TABLE

STEERING KNUCKLE BOLT TORQUE SPECIFICATIONS:
Camber adjusting bolt values, bolt identification and part number information for current production models can also b
WARRANTY INFORMATION:*
*
Warrantable only for 12 months or 12,500 miles from date-of-first-use or demo date, whichever occurs first. Covera
Alignment: Technical Service BulletinsAlignment - Specifications In Degrees

REF.: SUSPENSION
NO.: SU003-96
DATE: MARCH 29, 1996
MODEL: ALL MODELS
1996 MY WHEEL ALIGNMENT SPECIFICATIONS



For your reference listed are the alignment specifications for all 1996 model year vehicles.
> Maintenance > Alignment > System Information > Specifications > Alignment Specifications
Alignment: SpecificationsAlignment Specifications
ALIGNMENT SPECIFICATIONS
FRONT
Camber, Caster, Steering Axis Inclination
Measuring Point Reference
Toe-In
REAR
Camber
Toe-In
> Maintenance > Alignment > System Information > Specifications > Alignment Specifications > Page 611
> Maintenance > Alignment > System Information > Specifications > Page 612
Alignment: Tools and Equipment

Equipment
Tire pressure gaugeDial indicator with magnetic baseWheel balancer

> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications
Fuel Pressure: Specifications

Fuel Pressure Specifications
With Fuel Pressure Regulator vacuum hose disconnected ..............................................................................................

> Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 617
Fuel Pressure: Testing and Inspection
1. CHECK FUEL PUMP OPERATION
- Connect the TOYOTA hand-held tester to the DLC3.
- Turn ignition switch ON and TOYOTA hand-held tester main switch ON.
NOTICE: Do not start the engine.
- Select the active test mode on the TOYOTA hand-held tester.
Please refer to the TOYOTA hand-held tester operator's manual for further details.
- If you have no TOYOTA hand-held tester. connect the positive (+) and negative (-) leads from the battery to t
(See step 2 in fuel pump inspection)
- Check that there is pressure in the hose from the fuel filter.
HINT:
At Fusible link
this time, you will hear fuel return noise.If there is no pressure, check the following parts:-
- H-fuse (AM2 30A)
- Fuses (EFI 15A. IGN 10A)
- EFI main relay
- Fuel pump
- Wiring connections
- Remove TOYOTA hand-held tester.
2. CHECK FUEL PRESSURE
- Check that the
Disconnect the battery
negativevoltages is above
(-) terminal 12from
cable volts.the battery.

- Remove the union bolt and 2 gaskets, and disconnect the fuel in let hose from the delivery pipe.
HINT:
Put a suitable container or shop rag under the delivery pipe.
-- Slowly loosen the union bolt.
- Install the fuel inlet hose and SST (pressure gauge) to the delivery pipe with 3 new gaskets and SST (union bo
Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
- Wipe off any splattered gasoline.
-
Using SST, connect terminals +B and FP of the DLC1.SST 09843-18020
- Reconnect the negative (-) terminal cable to the battery.
- Measure the fuel pressure.
Fuel pressure: 265 - 304 kPa(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)

- If pressure is high, replace the fuel pressure regulator.
-
Fuel hoses
If pressure and check
is low, connections
the following parts:-
- Fuel pump
- Fuel filter
- Fuel pressure regulator
- Remove the SST. SST 09483-18020
- Start the engine.
- Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end.
- Measure the fuel pressure at idle.
Fuel pressure: 265 - 304 kPa

(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)
- Reconnect the vacuum sensing hose to the fuel pressure regulator.

Fuel pressure: 206 - 255 kPa(2.1 - 2.6 kgf/ sq.cm, 31 - 37 psi)

- If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator.
- Stop the engine.
- Check that the fuel pressure remains as specified for 5 minutes after the engine is stopped.
Fuel pressure: 147 kPa (1.5 kgf/ sq.cm, 21 psi) or more
- If pressure is not as specified, check the fuel pump, pressure regulator and/or injector.
-
After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove
- Reconnect the fuel inlet hose to the delivery pipe with 2 new gaskets and the union bolt.
Torque: 29 N.m (300 kgf.cm. 22 ft.lbf)

- Check for fuel leakage.
> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis
Air/Fuel Mixture: Testing and Inspection
HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations.
1. INITIAL CONDITIONS
- Engine at normal operating temperature
- Air cleaner installed
- All pipes and hoses of air induction system connected
- All accessories switched OFF
- All vacuum lines properly connected
HINT: All vacuum hoses for EGR systems, etc. should be properly connected.
- SFI system wiring connectors fully plugged

- Ignition timing set correctly
- Transmission in neutral position
- Tachometer and CO/HC meter calibrated by hand
2. START ENGINE3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS4. INSERT CO/HC METER
HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the a
Troubleshooting
Check
If the oxygen
CO/HC sensor operation.
concentration does not comply with regulations, perform troubleshooting in the order given below.
> Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 623

(See Oxygen Sensor Inspection under Computers and Controls System)
- See the table on the next page for possible causes, and then inspect and correct the applicable causes if necess
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Recalls for Idle Speed: > NHTSA96E001000 > Dec > 95 > Re
Control Systems
Idle Speed: RecallsRecall 96E001000: Defective Cruise Control Systems
These cruise control systems fail to hold the speed set by the driver and can accelerate above the intended set speed. Un
Dealers will replace these cruise control assemblies.
System: Fuel; Throttle linkages and control
Equipment description: Aftermarket cruise control system installed on certain Toyota passenger vehicles and light duty
The dealers would be located in the following states: Florida, Alabama, Georgia, North Carolina, and South Carolina fo
Note: Owners who take their vehicles to an authorized dealer in these affected states, on an agreed upon service date an
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > NHTSA96E
96E001000: Defective Cruise Control Systems
Idle Speed: All Technical Service BulletinsRecall 96E001000: Defective Cruise Control Systems
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom for Idle Speed: > NHTSA96E001000 > Dec > 9
Cruise Control Systems
Idle Speed: By SymptomRecall 96E001000: Defective Cruise Control Systems
> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 642
Idle Speed: SpecificationsControlled Idle Speed Specifications

Controlled Idle Speed Specifications
Idle Speed With Accesories Off 650 - 750 rpm
With A/C On With Magnetic Clutch Not Engaged approx. 650 rpm
With Magnetic Clutch Engaged approx. 900 rpm

> Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 643
Idle Speed: Testing and Inspection

- All operating accessories switched OFF
2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
(See ignition timing inspection and adjustment)
3. INSPECT IDLE SPEED

- Race the engine at 2,500 rpm for approx. 90 seconds.
- Check the idle speed.
Idle speed (w/ Cooling fan OFF): 700 50 rpm
- If the idle speed is not as specified, check the IAC system.

4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL
> Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair
Fuel Pressure Release: Service and Repair

FUEL PRESSURE RELEASE PROCEDURE
1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe the following
- Put a container under the connection.
- Slowly loosen the connection.
- Disconnect the connection.
- Plug the connection with a rubber plug.
2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures:
Union Bolt Type:

Always use a new gasket.
-- Tighten the union bolt by hand.
- Tighten the union bolt to the specified torque.
Torque: 29.5 N.m (300 kgf.cm, 22 ft.lbf)
Apply a light coat of engine oil to the flare and tighten the flare nut by hand.
-
Using SST, tighten the flare nut to the specified torque.SST 09631-22020

Flare Nut Type:
- HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

> Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
Firing Order: Specifications
FIRING ORDER: 1 3 4 2
> Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
Number One Cylinder: Locations
> Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications
Ignition Cable: Specifications

maximum resistance .............................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 658
Ignition Cable: Testing and Inspection

HIGH-TENSION CORDS INSPECTION
1. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS

- Disconnect the high-tension cords at the rubber boot.
- Do not pull on the cords.
NOTICE: Pulling on or bending the cords may damage the conductor inside.
2. DISCONNECT HIGH-TENSION CORDS FROM DISTRIBUTOR CAP

- Using a screwdriver, lift up the lock claw and disconnect the holder from the distributor cap.
- Disconnect the high-tension cord at the grommet. Do not pull on the cords.
3. INSPECT HIGH-TENSION CORD RESISTANCE

- Using an ohmmeter, measure the resistance.
maximum resistance: 25 kohm per cord
- If the resistance is greater than maximum, check the terminals.

- If necessary, replace the high-tension cord.
> Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 659

4. RECONNECT HIGH-TENSION CORDS TO DISTRIBUTOR CAP
- Connect the holder and grommet portion to the distributor cap as shown the illustration.
NOTICE: Check that the holder is correctly installed to the grommet and distributor cap as shown In the illus
- Check that the lock claw of the holder is engaged by lightly pulling the holder.
5. RECONNECT HIGH-TENSION CORDS TO SPARK PLUGS

- Secure the high-tension cords with the clamps as shown in the illustration.
> Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications
Distributor: Specifications
Torque ..................................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 663
Distributor: Testing and Inspection

DISTRIBUTOR INSPECTION
NOTICE: "Cold" and "Hot" in the following sentences express the temperature of the coils themselves."Cold"
1. DISCONNECT DISTRIBUTOR CONNECTOR2. REMOVE DISTRIBUTOR CAP3. REMOVE ROTOR4. REM

Ignition Coil
5. INSPECT PRIMARY COIL RESISTANCE

- Using an ohmmeter. measure the resistance between the positive (+) and negative (-) terminals.
Primary coil resistance:Cold: 0.36 - 0.55 ohmHot: 0.45 - 0.65 ohm

- If the resistance is not as specified, replace the ignition coil.
6. INSPECT SECONDARY COIL RESISTANCE

- Using an ohmmeter, measure the resistance between the positive (+) and high-tension terminals.
Secondary coil resistance:Cold: 9.0 - 15.4 K ohmHot: 11.4 - 18.1 K ohm

Distributor

7. INSPECT AIR GAP
- Using a feeler gauge, measure the air gap between the signal rotor and pickup coil projection.
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)
- If the air gap is not as specified, replace the distributor housing assembly.
8. INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE

Pickup coil resistance:Cold: G (+) and G(-): 185 - 275 ohmHot: G (+) and G(-): 240 - 325 ohm
- If the resistance is not as specified, replace the distributor housing assembly.
9. REINSTALL IGNITION COIL DUST COVER
10. REINSTALL ROTOR11. REINSTALL DISTRIBUTOR CAP12. RECONNECT DISTRIBUTOR CONNECTOR

Distributor: Service and Repair
COMPONENTS FOR REMOVAL AND INSTALLATION
DISTRIBUTOR REMOVAL

- Disconnect the high-tension cord at the grommet. DO NOT pull on the cord.
NOTICE: Pulling on or bonding the cords may damage the conductor inside.
2. DISCONNECT DISTRIBUTOR CONNECTOR3. REMOVE DISTRIBUTOR
- Remove the mounting bolt, and pull out the distributor.
- Remove the 0-ring from the distributor housing.

COMPONENTS FOR DISASSEMBLY AND ASSEMBLY
DISTRIBUTOR DISASSEMBLY
1. REMOVE DISTRIBUTOR CAP
- Remove the 3 bolts and distributor cap.
2. REMOVE ROTOR3. REMOVE IGNITION COIL DUST COVER

- Remove the dust cover.
- Remove the gasket.
4. REMOVE IGNITION COIL

- Remove the 2 nuts, and disconnect the 3 wires from the ignition coil terminals.
- Remove the 4 screws and ignition coil.

5. REMOVE CORD CLAMP
- Disconnect the connector from the cord clamp.
- Remove the screw and cord clamp.
6. REMOVE CONDENSER
- Remove the screw and condenser.
INSPECT SHAFT
Turn the shaft and check that it is not rough or worn.If it feels rough or worn, replace the distributor housing asse
DISTRIBUTOR ASSEMBLY
1. INSTALL CONDENSER
- Install the condenser with the screw.
2. INSTALL CORD CLAMP
- Install the cord clamp with the screw.
- Connect the connector to the cord clamp.
3. INSTALL IGNITION COIL
- Remove any old packing (FIPG.) material.
- Apply seal packing to the ignition coil installing surface of the housing as shown in the illustration.

Seal packing:Part No. 0S826-00080 or equivalent
- Install the ignition coil with the 4 screws.
- Connect the 3 wires to the ignition coil terminals with the 2 nuts as shown in the illustration.
NOTICE:
When connecting the wires to the ignition coil, Insert both properly into their grooves found on the side of
-- Be sure the wires do not contact with signal rotor or distributor housing.
4. INSTALL IGNITION COIL DUST COVER

- Install a new gasket to the distributor housing.
- Install the dust cover.
5. INSTALL ROTOR6. INSTALL DISTRIBUTOR CAP

- Install the distributor cap with the 3 bolts.
DISTRIBUTOR INSTALLATION

1. SET NO.1 CYLINDER TO TDC/COMPRESSION
- Turn the crankshaft clockwise, and position the slit of the intake camshaft as shown in the illustration.
2. INSTALL DISTRIBUTOR
- Install a new O-ring to the distributor housing.
- Apply a light coat of engine oil on the O-ring.
- Align the cutout portion of the coupling with the groove of the housing.
- Insert the distributor, aligning the bolt hole of the flange with that of the bolt hole on the cylinder head.
- Tighten the mounting bolt.

3. CONNECT HIGH-TENSION CORDS TO DISTRIBUTOR CAP4. CONNECT DISTRIBUTOR CONNECTOR5
> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications
Spark Plug: SpecificationsRecommended plugs

Recommended plugs
Recommended type ND K16R-U
NGK BKR5EYA
Plug gap 0.031 in

> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 674
Spark Plug: SpecificationsSpark Plug Type, Gap and Torque

Torque .................................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 675
Spark Plug: Testing and Inspection

SPARK PLUGS INSPECTION
1. DISCONNECT HIGH -TENSION CORDS FROM SPARK PLUGS2. REMOVE SPARK PLUGS
- Using a 16 mm plug wrench, remove the spark plug.
3. CLEAN SPARK PLUGS
- Using a spark plug cleaner or wire brush, clean the spark plug.
4. VISUALLY INSPECT SPARK PLUGS

- Check the spark plug for electrode wear, thread damage and insulator damage.
- If abnormal, replace the spark plug.
Recommended spark plug:ND: K16R-UNGK: BKR5EYA
5. ADJUST ELECTRODE GAP

- Carefully bend the outer electrode to obtain the correct electrode gap.
Correct electrode gap: 0.8 mm (0.031 in.)
6. INSTALL SPARK PLUGS

- Using a 16 mm plug wrench, install the spark plug.

> Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications
Compression Check: Specifications

Compression Pressure at 250 rpm
Std. ...................................................................................................................................................................................
Intake Manifold Vacuum

At Idle Speed ....................................................................................................................................................................
> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart
Valve Clearance: SpecificationsAdjusting Shim Selection Chart

> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 683

> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 684
Valve Clearance: SpecificationsService Specifications

Valve clearance (Cold):
Intake ........................................................................................................................................................................... 0.
> Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 685
Valve Clearance: Adjustments


VALVE CLEARANCE INSPECTION AND ADJUSTMENT
HINT: Inspect and adjust the valve clearance when the engine is cold.
1. REMOVE CYLINDER HEAD COVER

(a) Disconnect the following wires and clamps:
(1) Alternator connector(2) Alternator wire(3) Oil pressure switch connector(4) Two wire clamps
(b) Remove the two bolts and wire harness protector.
(c) Disconnect the wire harness from the cylinder head cover.
(d) Disconnect the high - tension cords at the rubber boot. Do not pull on the high-tension cords.
(e) Disconnect the PCV hoses from the cylinder head cover.

(f) Remove the four cap nuts, seal washers, cylinder head cover and gasket.
(a) Turn the crankshaft pulley and align its groove with the timing mark "0" of the No.1 timing belt cover.
(b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, tu
(360).
3. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.

- Using a thickness gauge, measure the clearance between the valve lifter and camshaft.
-
Record the out - of - specification valve clearance measurements. They will be used later to determine the
Intake: 0.15 - 0.25 mm (0.006 - 0.010 in.)Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 in.)

(b) Turn the crankshaft pulley one revolution (3600) and align the its groove with timing mark "0" of the No.1 tim
(c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))
4. ADJUST INTAKE VALVE CLEARANCE

A. Remove intake camshaft
NOTICE:
Since the thrust clearance of the camshaft is small. the camshaft must be kept level while it is being removed. If
(a) Turn the crankshaft pulley so that the hole in the sub-gear (which sets the sub-gear to the camshaft drive g
HINT: The above state allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their v
(b) Remove the two bolts and No.1 bearing cap.

(c) Secure the intake camshaft sub-gear to the drive gear with a service bolt.
Recommended service bolt:Thread diameter: 6 mm Thread pitch: 1.0 mmBolt length: 16 - 20 mm (0

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been el
(d) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.(e) Rem
HINT:
If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the two bolts.
NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.
B. Remove adjusting shim

Remove the adjusting shim with a small screwdriver.
C. Determine the replacement adjusting shim size by following Formula or Charts:

(a) Using a micrometer, measure the thickness of the removed shim.(b) Calculate the thickness of a new shim
T: Thickness of removed shim A: Measured valve clearance N: Thickness of new shim

Intake: N = T + (A - 0.20 mm (0.008 in.))
(c) Select a new shim with a thickness as close as possible to the calculated value.
HINT: Shims are available in 16 sized in increments of 0.05 mm (0.0020 in.), from 2.55 mm (1.0039 in.)
D. Install new adjusting shim
Place a new adjusting shim on the valve lifter.
E. Install intake camshaft
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed
(a) Turn the crankshaft pulley, set the intake camshaft so the knock pin is slightly above the top of the cylind

(b) Apply MP grease to the thrust portion of the camshaft.(c) Engage the intake camshaft gear to the exhaust
NOTICE: There are also timing marks (for TDC) on each gear as shown in the illustration. Do not use the
(d) Roll down the intake camshaft onto the bearing journals while engaging gears with each other.
HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their
(e) Install the four bearing caps in their proper locations.
(f) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.(g) Install and
(h) Remove the service bolt.

(i) Install the No.1 bearing cap with the arrow mark facing forward.
NOTICE:
If the No.1 bearing cap does not fit properly, push the camshaft gear backwards by prying apart the cylind
(j) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.(k) Install and
F. Recheck valve clearance
5. ADJUST EXHAUST VALVE CLEARANCE

A. Remove adjusting shim
(a) Turn the crankshaft so that the cam lobe of the camshaft on the adjusting valve upward.(b) Position the no
(c) Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Rem
SST: 09248-55020 (09248-05011, 09248-05021)
HINT:
- Apply
side, atSST (B) atangle.
a slight slight angle on the side marked with "9", at the position shown in the illustration.- Wh

- The shape of the cam makes it difficult to insert SST (B), from the intake side to the No.3 rear. For this s
the exhaust side instead.
(d) Remove the adjusting shim with a small screwdriver and magnetic finger.
B. Determine replacement adjusting shim size by following Formula or Charts:
T: Thickness of removed shimA: Measured valve clearanceN: Thickness of new shim

Exhaust: N = T + (A - 0.30 mm (0.012 in.))
HINT: Shims are available in 16 sizes, in increments of 0.05 mm (0.0020 in.), from 2.55 mm (1.0039 in.)
C. Install new adjusting shim

(a) Place a new adjusting shim on the valve lifter.(b) Using SST (A), press down the valve lifter and remove

SST: 09248-55020 (09248-05011. 09248-05021)
D. Recheck valve clearance
6. INSTALL CYLINDER HEAD COVER

(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
(c) Install the gasket to the cylinder head cover.
(d) Install the cylinder head cover with the four seal washers and cap nuts.
Torque. 5.9 N.m (60 kgf.cm, 52 in.lbf)
(e) Connect the PCV hoses to the cylinder head cover.(f) Connect the four high-tension cords to the spark plugs
(g) Install the engine wire harness and protector with the two bolts.(h) Connect the following wires and clamps:

> Maintenance > Timing Belt > Component Information > Specifications
Timing Belt: SpecificationsService Specifications

Service Specifications
Service Interval Replacement 60,000 miles
Timing Belt Deflection 5-6 mm

> Maintenance > Timing Belt > Component Information > Specifications > Page 700
Timing Belt: Testing and Inspection

INSPECT TIMING BELT
Do not bend,
NOTICE: - twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley
If there are any defects. as shown in the illustration, check the following points:
(a) Premature parting

- Check the proper installation.
- Check the timing cover gasket for damage and proper installation.
(b) If the belt teeth are cracked or damaged. check to see if either camshaft or water pump is locked.
(c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pull
(d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth. check the timing cover for damage. correct gasket installation, and
pulley teeth. If necessary, replace the timing belt.
> Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal
Timing Belt: Service and RepairTiming Belt Removal

> Maintenance > Timing Belt > Component Information > Service and Repair > Timing Belt Removal > Page 703

TIMING BELT REMOVAL
1. Remove washer tank.
2. With Cruise Control System: Remove cruise control actuator.
3. Remove RH front wheel.
4. Remove RH engine under cover.
5. Loosen water pump pulley bolts and remove alternator drive belt.

(a) Stretch the belt tight and loosen the water pump pulley bolts.
(b) Loosen the pivot bolt and adjusting lock bolt.
(c) Loosen the adjusting bolt, and remove the drive belt.
6. With A/C: Remove A/C compressor without disconnecting hoses.
(a) Loosen the idler pulley mounting bolt A.
(b) Loosen the adjusting bolt B and remove the drive belt
(c) Disconnect the A/C compressor connector.
(d) Remove the 4 compressor mounting bolts.
(e) Move the compressor aside and suspend it.
7. With A/C: Remove A/C compressor mounting bracket.
8. With PS: Remove PS pump drive belt.

(a) Loosen the pivot and lock bolts.

(b) Swing PS pump toward the engine and remove the drive belt.
9. Disconnect connector from ground wire on RH fender apron.
10. Remove RH engine mounting insulator.
(a) Set the jack to the engine.
HINT: Place a wooden block between the jack and engine.
(b) With Cruise control system: Remove the 3 bolts, ground wire and actuator bracket.
(c) With A/C: Remove the screw, bolt and bracket.
(d) With A/C: Remove the bolt and damper.
(e) Remove the 5 bolts, 2 nuts and RH mounting insulator.
11. Remove water pump pulley.

12. Remove spark plugs.
13. Remove cylinder head cover.
(a) Disconnect the generator wire and clamp.
(b) Remove the 2 bolts and wiring harness protector.
(c) Disconnect the engine wire harness from the cylinder head.
(d) Disconnect the 2 PCV hoses from the cylinder head cover.

(e) Remove the 4 cap nuts, 4 seal washers, cylinder head cover and gasket.
14. Set No.1 Cylinder to TDC/Compression.
(360).
15. Remove No.3 and No.2 timing belt covers. Remove the 6 bolts and timing belt covers.
HINT (When re-using timing belt)
: Place matchmarks on the timing belt and camshaft timing pulley, and matchmarks on the timing belt tomatch th
16. Remove crankshaft pulley.

SST 09213-70010 and 09330-00021(a) Using , remove the pulley belt.
SST 09950-50010(09951 -05010,09952-05010. 09953-05020, 09954-05020)(b) Using . remove the pulley.
17. Remove no.1 timing belt cover. Remove the 3 bolts and timing belt cover.
18. Remove timing belt guide.

19. Remove timing belt.
HINT (When re-using timing belt):

Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks onthe tim

(a) Loosen the mounting bolt of the idler pulley and shift pulley toward the left as far as it will go and then tempo
(b) Remove the belt.
20. Remove idler pulley and tension spring.
21. Remove camshaft timing pulley. If the pulley cannot be removed by hand, use 2 screwdrivers.
NOTICE: Position shop rags as shown to prevent damage.
22. Remove camshaft timing pulley. Hold the hexagonal head wrench portion of the camshaft with a wrench, and rem
NOTICE: Be careful not to damage the cylinder head with the wrench.
Timing Belt: Service and RepairTiming Belt Installation


TIMING BELT INSTALLATION
1. Install camshaft timing pulley.

(a) Align the camshaft knock pin with the knock pin groove on the pulley side with "K" mark, and slide on the tim
(b) Temporarily install the timing pulley bolt.
(c) Hold the hexagonal wrench head portion of the camshaft with a wrench, and tighten the timing pulley bolt.
2. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the flange side inward.
3. Temporarily install idler pulley and tension spring.
(a) Install the idler pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.

(c) Push the pulley toward the left as far as it will go and tighten the bolt.
4. Set No.1 cylinder to TDC/Compression.

(a) Turn the hexagonal wrench head portion of the camshaft, and align the hole of the camshaft timing pulley wit
cap.
(b) Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pull
5. Install timing belt.
(a) Install the timing belt on the crankshaft timing pulley.

Align the points marked during removal. and install the belt with the arrow pointing in the direction ofengine rev
(b) Install the timing belt guide, facing the cup side outward.
(c) Install the No.1 timing belt cover with the 3 bolts.
Torque: 7.4 N.m (75 kgf.cm, 65 in..lbf)
(d) Temporarily install the crankshaft pulley with the pulley bolt.

(e) Turn the crankshaft pulley, and align its groove with the timing mark 0 of the No.1 timing belt cover.
- Support the timing belt, so that the meshing of the crankshaft timing pulley and timing belt does not shift.
- Check that the matchmark on the timing belt matches the end of No.1 timing belt cover.
- Align the matchmarks of the timing belt and camshaft timing pulley.
(f) Install the timing belt, checking the tension between the crankshaft timing pulley and camshaft timing pulley.
6. Check valve timing and timing belt tension.
(a) Remove the grommet and loosen the timing belt idler pulley mounting bolt.
(b) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.


(c) Check that each pulley aligns with the marks as shown in the illustration. If the timing marks do not align, rem
it.
(d) Tighten the timing belt idler pulley mounting bolt.
(e) Install the grommet to the No.1 timing belt cover.
7. Reference:
Check timing belt deflection.Check that there is belt deflection at the position indicated in the illustration.
Belt deflection: 5 - 6 mm (0.20- 0.24 in.) at 20 N (2 kgf, 4.4 lbf)
If the deflection is not as specified, readjust with the idler pulley.
8. Install timing belt covers. Install the No.2 and No.3 timing belt covers with the 6 bolts.
Torque: 7.4 N.m (75 kgf.cm. 65 in.lbf)
9. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
SST 09213-70010,09330-00021(b) Using , install the pulley bolt.
Torque: 118 Nm (1,200 kgfcm, 87 ft.lbf)
10. Install cylinder head cover.

(d) Install the cylinder head cover with the 4 seal washers and 4 cap nuts. Uniformly tighten the cap nuts in sever
(e) Connect the 2 PCV hoses to the cylinder head cover.
(f) Install the engine wire harness and wiring harness protector with the 2 bolts.
(g) Connect the generator wire and clamp.
11. Install spark plugs.
12. Temporarily install water pump pulley.
13. Install RH engine mounting insulator.
(a) Install the mounting insulator with the 5 bolts and 2 nuts.
Torque:A: 64 N.m (650 kgf.cm, 47 ft.lbf)B: 52 N.m (530 kgf.cm, 38 ft.lbf)C: 25 N.m (260 kgf.cm, 19 ft.lb
(b) With A/C: Install the damper with the bolt.
(c) With A/C: Install the bracket with the bolt and screw.
(d) With Cruise control system: Install the actuator bracket and ground wire with the 3 bolts.
14. Connect ground connector to ground wire on RH fender apron.
15. With PS: Install and adjust PS drive belt.
16. With A/C: Install a/c compressor mounting bracket.
17. With A/C: Install a/c compressor.

18. With A/C: Install and adjust A/C drive belt.
19. Install and adjust generator drive belt.
Tighten the 4 water pump pulley bolts.
20. Install RH engine under cover.
21. Install RH front wheel.
22. With cruise control system: Install cruise control actuator.
23. Install washer tank.

> Maintenance > Drive Belt > Component Information > Service and Repair > A/C
Drive Belt: Service and RepairA/C

DRIVE BELT REMOVAL
1. Remove Washer Reserve Tank
2. Remove Alternator Drive Belt
3. Loosen Idle Pulley Lock Nut
39 N.m (400 kgf.cm, 29 ft.lbf)Torque:
4. Loosen Adjusting Bolt And Remove Drive Belt
DRIVE BELT INSTALLATION

> Maintenance > Drive Belt > Component Information > Service and Repair > A/C > Page 721
Drive Belt: Service and RepairAlternator
GENERATOR INSTALLATION
1. INSTALL GENERATOR
(a) Mount generator on the generator bracket with the pivot bolt. nut and adjusting lock bolt. Do not tighten the b
2. INSTALL DRIVE BELT
(a) Install the drive belt.(b) Using a belt tension gauge, measure the drive belt tension.Belt tension gauge: Nippo
Drive belt tension:
175 5 lbf
115 20. lbfNew Belt =,Used belt =
(c) Tighten the pivot and adjusting lock bolt.
HINT:
- "New belt" refers to a belt which has been used less than 5 minutes on a running engine.
- "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.
- After installing a belt, check that it fits properly in the ribbed grooves.
- Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.
- After installing a new belt. run the engine for about 5 minutes and recheck the belt tension.
3. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY4. PERFORM ON-VEHICLE INSPECTION

> Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - New Oil Filter/Wrench
Oil Filter: Technical Service BulletinsEngine - New Oil Filter/Wrench

REF.: SPECIAL SERVICE TOOLS
NO.: SS95-004
DATE: NOVEMBER 10, 1995
MODEL: ALL MODELS
NEW OIL FILTER WRENCH
Beginning in 1996, Toyota will be standardizing the size of many of its oil filters to the three inch industry standard. Th
Three inch oil filter wrenches are readily available from parts stores and tool dealers, however, for your convenience, O
> Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 731
Oil Filter: Tools and Equipment
Toyota Oil Filter Wrench Set
AST tool# TOY 300
This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyo
- Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters.
Contact AST for pricing.
Assenmacher Specialty Tools1-800-525-2943
This Kit Contains the Following Tools:

TOY 640 - Toyota Oil Filter Wrench
> Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 732

TOY 730 - 73mm Toyota Oil Filter Wrench
M 0219 - 74mm Oil Filter Wrench

> Maintenance > Hoses > System Information > Service Precautions
Hoses: Service Precautions
SERVICE PRECAUTIONS
-ToAfter servicing
prevent vehicleadamage,
hose, check for observe
always leaks before and after test
the following driving the vehicle.
precautions:
- Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa.
- Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place
-
When replacing hoses which are attached to the engine on one end and the frame or body on the other end, alway
> Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Required Brake Fluid SAE DOT3

> Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications

SAE J1703 or FMVSS No. 116 DOT 3Specified type ......................................................................................................
> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications
Capacity Manual Transmission Nippondenso radiator 5.8 qt (US)
Harrison radiator 6.6 qt (US)
Automatic Transmission Nippondenso Radiator 6.6 qt (US)
Coolant type Ethylene glycol

> Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 747
Coolant: Fluid Type Specifications
Do not use alcohol type anti-freeze or water without anti-freeze.
Specified Type Ethylene-glycol Based Anti-freeze/coolant

Toyota brand recommended.
Coolant Concentration 50% Anti-freeze / 50% Distilled Or Demineralized Water

> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications
Differential Fluid - A/T: Capacity Specifications

AFTYPE ..............................................................................................................................................................................
CAPACITY, Refill
Camry, Avalon 4-cyl ............................................................................................................................................................
Corolla 3-speed ....................................................................................................................................................................
Celica 2.2L ...........................................................................................................................................................................

> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 752
Differential Fluid - A/T: Fluid Type Specifications
Differential Fluid Type (3 Speed A/T) ................................................................................................................. ATF D-I

> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 753
Differential Fluid - A/T: Testing and Inspection
To check differential fluid level:
Remove the filler plug and check differential fluid level.

> Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 754
Differential Fluid - A/T: Service and Repair

ATF Replacement - 3 Speed A/T
1. Using a hexagon wrench, remove the drain plug and drain the fluid.2. Using a hexagon wrench, install the drain pl
ATF D-II or DEXRON III (DEXRON II)Fluid type:
5. Check differential fluid level. Remove the filler plug and check differential fluid level.
> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Fluid Interchangeability
Fluid - A/T: Technical Service BulletinsA/T - Fluid Interchangeability
TRANSMISSION & CLUTCHTC003-99
Title:AUTOMATIC TRANSMISSION FLUIDS
Models:All Models
May 21, 1999
REVISION NOTICE:
The information contained in this TSB updates TC003-98 dated June 19, 1998.
Introduction
Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify
Please refer to the following table for the interchangeability between each ATF.
Affected Vehicles
^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV.
NOTICE:
With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed.
Parts Information
SIZE NEW PART NUMBER PART NAME
4 Liter 08886-01705 ATF Type T-IV

> Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Fluid Interchangeability > Page 759
Fluid - A/T: Technical Service BulletinsA/T - Fluid Type T-IV Replaces Type T-II
June 19, 1998
Title:AUTOMATIC TRANSMISSION FLUID TYPE T-IV
Models:ALL MODELS
Introduction
The introduction of Automatic Transmission Fluid type T-IV makes type T-II obsolete. Use type T-IV for all applicatio
Affected Vehicles
^ All vehicles with Automatic Transmissions specified to use ATF Types T-II or T-IV.
Parts Information
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications

A/T Fluid (w/o Differential Oil)
Drain and Fill .......................................................................................................................................................................

> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 762
Fluid - A/T: Fluid Type Specifications
A/T Fluid
Type ....................................................................................................................................................................................
> Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 763
Fluid - A/T: Testing and Inspection

PRELIMINARY CHECK
1. CHECK FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature.
-
ATF temperature: 70 - 80 C (158 - 176 F)
- Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does n
(a) Park the vehicle on a level surface and set the parking brake.(b) With the engine idling and the brake pedal de
position.
(c) Pull out the oil level gauge and wipe it clean.(d) Push it back fully into the pipe.(e) Pull it out and check that t
Fluid type: ATF D-II or DEXRON III (DEXRON II)
NOTICE: Do not overfill.
2. CHECK FLUID CONDITION

If the fluid smells burnt or is black, replace it.
3. REPLACE ATF
(a) Using a hexagon wrench, remove the drain plug and drain the ATF.(b) Using a hexagon wrench, install the dr

Drain end refill: 2.5 liters: (2.6 US qts, 2.2 Imp.qts)
(d) Start the engine and shift the selector into all positions from the P position through the L position and then shi
4. REPLACE DIFFERENTIAL FLUID IF NECESSARY
5. CHECK DIFFERENTIAL FLUID LEVEL

6. INSPECT AND ADJUST THROTTLE CABLE

(a) Fully depress the accelerator pedal and check that the throttle valve opens fully.
HINT; If the throttle valve does not open fully, adjust the accelerator link.
(a) Using a hexagon wrench, remove the drain plug and drain the fluid.(b) Using a hexagon wrench. install the dr

(b) Fully depress the accelerator.(c) Loosen the adjustment nuts.(d) Adjust the outer cable so that the distance bet
Standard boot and cable stopper distance:

0 - 1 mm (0-0.04 in.)
(e) Tighten the adjusting nuts.(f) Recheck the adjustments.
7. INSPECT PARK/NEUTRAL POSITION SWITCH

(a) Remove the park/neutral position switch.
(b) Using an ohmmeter, check continuity between each terminal shown below when the shift lever is put in each
8. ADJUST SHIFT CONTROL CABLE
(a) Remove the engine under cover.(b) Loosen the nut on the control shaft lever.(c) Push the control shaft lever fu

9. ADJUST PARK/NEUTRAL POSITION SWITCH
If the engine will start with the shift selector in any position other than the N or P position, adjustment is required
Torque: 5.4 Nm (55 kgf.cm, 48 in.Ibf)
Idle speed: 75050 rpm (In the N position and A/C OFF)
Fluid - A/T: Service and Repair

(ATF)1. Replace Automatic Transmission Fluid , as follows:
a. Using a hexagon wrench, remove the drain plug and drain the fluid.b. Using a hexagon wrench, install the drai
(P) (L) P
70 - the
d. Start 80Cengine
(158 -and
176F) Check
shift the fluidinto
the selector level
allwith the normal
positions fluid
from the temperature
Park and
through the add and
Low as necessary.
then shift into the
> Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
M/T Fluid .............................................................................................................................................................................

> Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 772
Fluid - M/T: Fluid Type Specifications
M/T Fluid
Grade ....................................................................................................................................................................................
Viscosity ..............................................................................................................................................................................
> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid (3 speed type automatic transmission only)
Capacity ...............................................................................................................................................................................
> Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 777
Fluid - Differential: Fluid Type Specifications
Differential Fluid (3 speed automatic transmission only)
Type .....................................................................................................................................................................................
> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
CAPACITY, Refill:
Supra ....................................................................................................................................................................................
Camry, Avalon 4-cyl ............................................................................................................................................................
Celica 1.8L ...........................................................................................................................................................................

Tercel, Paseo ........................................................................................................................................................................
Corolla 1.6L .........................................................................................................................................................................
Capacity shown is without filter. When replacing filter, additional oil may be needed
[1] Preferred
> Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 782
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification ......................................................................................................................................... SH Energy C

> Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications

GENERAL SPECIFICATIONS
Power Steering Fluid ........................................................................................................................................................
> Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Alternative Refrigerants and Retrofits
Refrigerant: Technical Service BulletinsA/C - Alternative Refrigerants and Retrofits

Ref.: HEATING & AIR CONDITIONING
Date: NOVEMBER 29, 1996
No.: AC003-96
Model: ALL MODELS
Title: ALTERNATE REFRIGERANTS AND A/C RETROFIT
The E.P.A. has officially banned the manufacture of Refrigerant 12 (Freon) after January 1, 1996. As a result, surplus s
This uncertainty about the availability of R-12 has caused significant concerns for Toyota dealers when servicing HVA
ALTERNATE REFRIGERANTS:
Previously, the E.P.A. has endorsed other alternative refrigerants. These endorsements, combined with the uncertain fu
^ Poor system performance and leak detection capabilities.
^ Contamination of R-12 and R-134a during refrigerant recovery and recycling.
Recently the E.P.A. released a statement clarifying that approval of alternative refrigerants relates only to the toxicolog
TOYOTA MOTOR SALES, U.S.A. ENDORSES THE USE OF R-134A AS THE ONLY ACCEPTABLE ALTERNA
R-12 AVAILABILITY:
RETROFIT ISSUES:
Toyota has completed development of retrofit parts for all later model Toyota vehicles - using R-12 refrigerant. These p
The parts necessary for a typical retrofit will generally include:
^ Receiver Dryer
^ 0-Rings
^ Fittings
^ Labels
It is estimated that existing R-12 supplies will meet market demand in 1996. Beyond that, Toyota will supply R-12 to i
^ Oil
A TSB outlining retrofit procedures will be released when the retrofit kits become available.
For additional information, contact the Toyota Environmental Assistance Network Hotline at 1-800-542-3914.
> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications
Refrigerant: Capacity Specifications
Charge Volume 24.69 +/- 1.76 oz (US)

> Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 792
Refrigerant: Fluid Type Specifications
Type R134a
> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications
Refrigerant Oil: Capacity SpecificationsOil Capacity

Oil Capacity
When Replacing Receiver Add 20 cc
When Replacing Condenser Add 40 cc
When Replacing Evaporator Add 40 cc
When Replacing Compressor Add120 cc

> Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 797
Refrigerant Oil: Fluid Type Specifications
Type ND-OIL 8
> Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System
Brake Bleeding: Service and RepairBleeding the Brake System
CAUTION: Do not let brake fluid remain on a painted surface. Wash it off immediately.
NOTE: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air.
Filling Brake Reservoir With Brake Fluid
BRAKE FLUID BLEEDING

1. Fill brake reservoir with brake fluid.
Fluid: SAEJ17O3 or FMVSS No.116 DOT 3
2. Bleed Master Cylinder.
NOTE: If the Master Cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the M
(a) Disconnect the brake lines from the Master Cylinder.
Depressing Brake Pedal To Bleed Master Cylinder
(b) Slowly depress the Brake Pedal and hold it.

Blocking Off Outlet Plug
(c) Block off the outlet plugs with your fingers, and release the brake pedal.(d) Repeat (b) and (c) 3 or 4 times.
> Maintenance > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System > Page 802

3. Bleed brake line.
(a) Connect vinyl tube to Brake Caliper.(b) Depress the brake pedal several times, then loosen the bleeder plug w
4. Check fluid level in reservoir.
Check fluid level and add fluid if necessary.
> Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair
Air Bag(s) Arming and Disarming: Service and Repair
CAUTION:
90 seconds* Work must be started after the ignition switch is turned to the "LOCK" position and the negative (-) term
90 seconds
the battery. (The SRS is equipped with a back-up power source so that if work is started within of disconnecting the
* When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system wil
work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio
* Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs.* Do not expos
AIR BAG SYSTEM DISARMING
90seconds
The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deplo
1. Turn ignition to Lock, then disconnect battery ground cable.
2. 90 secondsWait at least after disconnection before beginning service or diagnostic procedures.
AIR BAG SYSTEM ARMING

1. Ensure ignition is in Lock position.
2. Connect battery ground cable.
3. 10 secondsWait at least before turning ignition from Lock position.
4. 6
Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately seconds. If l
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations
Fuse: Locations
> Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Page 810



Details

Body (Fig 19)
Locations
> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
Fuse Block: Locations

> Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 817



Details

Body (Fig 19)
Locations
> Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations
Fusible Link: Locations

> Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Page 824



Details

Body (Fig 19)
Locations
> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations

> Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 831



Details

Body (Fig 19)
Locations
> Maintenance > Service Reminder Indicators > System Information > Service Precautions
Service Reminder Indicators: Service Precautions
SERVICE PRECAUTION
All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the in
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update
Wheels: Technical Service BulletinsWheels - Balance Adapter Kit Update

Ref: SUSPENSION
No.: SU002-96 (REVISED)
Date: SEPTEMBER 6, 1996
Model: ALL MODELS
Title: WHEEL BALANCE ADAPTER KIT
To improve the accuracy of Dynamic Off-Car wheel balancing on all OEM Toyota five and six lug wheels, a precision
PART NUMBER INFORMATION:
NOTE:
Tires that have nylon belts must be warmed-up sufficiently by driving 4 to 5 miles at 45 m.p.h. before balancing. Th
BALANCE PROCEDURE:
The Haweka Flange Plate uses the wheel lug holes and a centering cone to center the wheel on the balancer arbor as the
1.
Use the centering cone and flange plate combination on all five and six lug steel and alloy Toyota wheels. On fou
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update > Page 843

2.
Verify that the centering cone fits inside the wheel center as well as inside the balance machine hub (see Figure 2
3. Always install the spring and centering cone toward the back side of the wheel (see Fig. 3).
For additional wheel balancer accessories, refer to the latest Toyota Approved Dealer Equipment catalog (P/N 00451-8
To place an order, please call Toyota Approved Dealer Equipment at 1 (800) 368-6787.
> Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update > Page 844
Wheels: Technical Service BulletinsWheels - Full Wheel Cover Application Caution
BODYBO028-97
October 3, 1997
Title: ANTI-ROTATION BAR NOT PRESENT ON TYPE "U" STYLED STEEL WHEELS
Models: Corolla (base grade)
Introduction
CAUTION:
Full wheel covers should not be Installed on a wheel without the anti-rotation bar. Wheel covers are not applicable
Affected Vehicles
Corolla (models 1714 and 1721) with 14" styled steel wheels from 1996 model year.
Parts Information
The anti-rotation bar welded to the steel rim of base grade Corolla (models 1714 & 1721) wheels is not installed on Ty
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front > Page 849
> Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 850
Wheel Bearing: Service and Repair
Rear Axle Hub And Carrier Removal

Note: Installation is in the reverse order of removal. After installation. check the ABS speed sensor signal and rear wh

1. Remove rear wheel.
103 N.m (1,050 kgf.cm, 76 ft.lbs)Torque:
2.3. Remove brake drum
4. Check bearing backlash and axle hub deviation

0.05 mm (0.0020 in.)(a) Place the dial indicator near the center of the axle hub and check the backlash in the bea
If greater then the specified maximum, replace the axle hub with bearing (W/ ABS) or bearing (W/O ABS).
(b) Using a dial indicator. check the deviation at the surface of the axle hub outside the hub bolt.
0.07 mm (0.0028 In.) Maximum: If greater then the specified maximum. replace the axle hub with bearing.
5. w/ABS:
REMOVE ABS SPEED SENSORRemove the bolt and speed sensor.

8 N.m (82 kgf.cm, 71 in.-lbf)Torque:
5. REMOVE REAR AXLE HUB.

(a) Remove the 4 bolts and rear axle hub.
80 N.m (820 kgf.cm. 59 ft.lbs)Torque:
(b) Remove the 0-ring.
Installation hint: Coat a new 0-ring with MP grease.
(c) Drum brake:(d) REMOVE BRAKE HOSE FROM SHOCK ABSORBER.(e) REMOVE THE BACKING PLA
6. REMOVE REAR AXLE CARRIER
(a) Loosen 3 nuts.Torque:

142 N.m (1,450 kgf.cm, 105 ft.lbs) 118 N.m (1,200 kgf.cm, 87 ft.lbs)Nut A: Nut B:
Installation hint: After stabilizing the suspension. torque the nuts.
(b) Remove the bolt and nut and disconnect the strut rod from the rear axle carrier.
91 N.m (930 kgf.cm, 67 ft.lbf) Torque: INSTALLATION HINT: After stabilizing the suspension, torque the
Note: When removing/installing bolt, stop the nut from rotating and loosen/torque the bolt.
(c) Remove the 3 nuts and bolts .
Installation hint: If reusing the 3 nuts, coat their threads with engine oil before applying the torque.
(d) Remove the rear axle carrier.
Rear Axle Hub Bearing Replacement
Note: If equipped with ABS, do not disassemble the rear axle hub and bearing.
1. Remove lock nut.
(a) Using a hammer and chisel. release the nut caulking.(b) Remove the lock nut.
2. Remove axle hub.
(a) Using SST, remove the axle hub from the bearing. SST 09950-40010
(b) Using a screwdriver. remove the oil seal from the inner race.(c) Using SST, remove the inner race (outside) fr

3. Install axle hub to bearing.
(a) Using SST and a press, install the axle hub to a new bearing.(b) Install a new lock nut. SST 09608-30012 (096
123 N.m (1.250 kgf.cm. 90 ft.lbs)Torque:
(c) Stake the lock nut.
> Maintenance > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Full Wheel Cover Application Caution
Wheel Cover: Technical Service BulletinsWheels - Full Wheel Cover Application Caution
BODYBO028-97
October 3, 1997
Introduction
CAUTION:
Affected Vehicles
Parts Information
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drive Axles - Front Hub Nut Replacement
Axle Nut: Technical Service BulletinsDrive Axles - Front Hub Nut Replacement
DRIVELINE/DIFFERENTIALDL001-98
MARCH 6, 1998
TITLE:FRONT AXLE HUB NUT REPLACEMENT
MODELS:'92 - '98 TERCEL, PASEO, COROLLA, CELICA, CAMRY'96 - '98 RAV4
Introduction
Due to a change of the friction control treatment on the nut thread, both types of Front Axle Hub Nuts (silver and black
NOTE:
When replacing the Front Axle Hub Nut the new part must be the same color as the old part. When replacing a Silver n
Affected Vehicles
- 1992-1998 Tercel, Paseo, Corolla, Celica, Camry and 1996-1998 RAV4s.
Parts Information
PART NUMBER PART NAME COLOR
90179-22020 Nut, Axle Hub Silver

90178-22001 Nut, Axle Hub Black
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front
> Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 865
> Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications

Wheel Fastener .....................................................................................................................................................................
> Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > SU00696 > Nov > 96 > Drivet
Axle Hub
Wheel Seal: All Technical Service BulletinsDrivetrain - Squeaking Noise From Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
Title: SQUEAKING NOISE FROM FRONT AXLE HUB
In order to eliminate squeaking noise from the seal in the front axle hub on 1996 Corollas, a change in the oil seal kit h
PRODUCTION EFFECTIVE:
Starting VIN: JT2*A02E*T0147156
JT2*A02E*T0110035
PARTS IDENTIFICATION:
The new silver color is visible only on the outer seal, the inner seal remains gold.

WARRANTY INFORMATION:
> Maintenance > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > SU00696 > Nov > 96 > Drivetrain - Squeaki
Wheel Seal: Customer InterestDrivetrain - Squeaking Noise From Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide.
Towing Information: Technical Service BulletinsVehicle - Towing Guide.
BULLETIN NUMBER:AX001-00
DATE:March 17, 2000
TITLE:TOYOTA "DINGHY" TOWING GUIDE
MODELS:All Models
INTRODUCTIONThe chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four w
CAUTION:
Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Mot
WARRANTY INFORMATION
APPLICABLE VEHICLES
> Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide. > Page 886

NOTE:
After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before ope
NOTE:
must
Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long
> Maintenance > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide. > Page 887
Towing Information: Technical Service BulletinsVehicle - Towing Guide
ACCESSORIESAX004-99
March 19, 1999
Title:TOYOTA "DINGHY" TOWING GUIDE
Models:
All Models
Introduction: The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on th
CAUTION:
Dinghy towing 6 vehicle behind a Motorhome requires special towing equipment and accessories. Please see your M
Affected Vehicles
- All Models
Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The tran
> Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications

Std. ...................................................................................................................................................................................

At Idle Speed ....................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: SpecificationsTorque Specifications

Torque Specifications
Camshaft Timing Pulley 43 ft.lb

> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
1. REMOVE VALVE LIFTERS AND SHIMS
HINT: Arrange the valve lifters and shims in correct order.
.
INSPECT VALVE LIFTERS AND LIFTER BORES(a) Using a caliper gauge, measure the lifter bore diameter o
28.005 - 28.026 mm (1.1026 - 1.1034 in.)Lifter bore diameter:
(b) Using a micrometer, measure the lifter diameter.

27.975 - 27.985 mm (1.1014 - 1.1018 in.)Lifter diameter:
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
> Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 900

(b) Check that the valve lifter rotates smoothly by hand.
> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer - Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: SpecificationsTorque Specification

Torque Specification
Crankshaft Pulley Bolt 87 ft.lb

> Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications
Piston Pin: Specifications
Cylinder Head Torque Sequence
Cylinder Head Torque

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 913

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 914

Intake ........................................................................................................................................................................... 0.
> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 915




(360).

-


NOTICE:


HINT:



Intake: N = T + (A - 0.20 mm (0.008 in.))
NOTICE:


NOTICE:

SST: 09248-55020 (09248-05011, 09248-05021)
HINT:
- Apply


Exhaust: N = T + (A - 0.30 mm (0.012 in.))


SST: 09248-55020 (09248-05011. 09248-05021)


> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Technical Service Bulletins > Valve Cover Oil Baffle - Damage Prevention
Valve Cover: Technical Service BulletinsValve Cover Oil Baffle - Damage Prevention
ENGINEEG007-02
Title:GENERAL MAINTENANCE TIP
Models:All '93 - '03 Models
March 22, 2002
Introduction
To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle
All 1993Vehicles^
Oil Filling Procedure
Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, rep
> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C
Drive Belt: Service and RepairA/C

DRIVE BELT REMOVAL
1. Remove Washer Reserve Tank
2. Remove Alternator Drive Belt
3. Loosen Idle Pulley Lock Nut
39 N.m (400 kgf.cm, 29 ft.lbf)Torque:
4. Loosen Adjusting Bolt And Remove Drive Belt
DRIVE BELT INSTALLATION

> Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > A/C > Page 939
Drive Belt: Service and RepairAlternator
Drive belt tension:
175 5 lbf
HINT:

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
CAPACITY, Refill:
Supra ....................................................................................................................................................................................
Camry, Avalon 4-cyl ............................................................................................................................................................
Celica 1.8L ...........................................................................................................................................................................

Tercel, Paseo ........................................................................................................................................................................
Corolla 1.6L .........................................................................................................................................................................
Capacity shown is without filter. When replacing filter, additional oil may be needed
[1] Preferred
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 945
Engine Oil: Fluid Type Specifications
Engine Oil
API Classification ......................................................................................................................................... SH Energy C

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - New Oil Filter/Wrench
Oil Filter: Technical Service BulletinsEngine - New Oil Filter/Wrench

REF.: SPECIAL SERVICE TOOLS
NO.: SS95-004
MODEL: ALL MODELS
NEW OIL FILTER WRENCH
Beginning in 1996, Toyota will be standardizing the size of many of its oil filters to the three inch industry standard. Th
Three inch oil filter wrenches are readily available from parts stores and tool dealers, however, for your convenience, O
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 950
Oil Filter: Tools and Equipment
Toyota Oil Filter Wrench Set
AST tool# TOY 300
This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyo
- Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters.
Contact AST for pricing.
Assenmacher Specialty Tools1-800-525-2943
This Kit Contains the Following Tools:

TOY 640 - Toyota Oil Filter Wrench
> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 951

TOY 730 - 73mm Toyota Oil Filter Wrench
M 0219 - 74mm Oil Filter Wrench

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Diagrams
Oil Pump: Diagrams

> Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Diagrams > Page 955


Oil Pump: Testing and Inspection

OIL PUMP DISASSEMBLY

1. REMOVE RELIEF VALVE
(a) Using snap ring pliers, remove the snap ring.(b) Remove the retainer, spring and relief valve.
2. REMOVE DRIVE AND DRIVEN ROTORS

Remove the 5 screws, pump body cover, O-ring. the drive and driven rotors.
OIL PUMP INSPECTION

1. INSPECT RELIEF VALVE
Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn't,

2. INSPECT DRIVE AND DRIVEN ROTORS
A. Inspect rotor body clearance

Using a thickness gauge, measure the clearance between the driven rotor and body.
Standard body clearance: 0.080 - 0.180 mm (0.0031 - 0.0071 in.)Maximum body clearance: 0.20 mm (0.
If the body clearance is greater than maximum, re place the rotors as a set. If necessary, replace the oil pump a
B. Inspect rotor tip clearance

Using a thickness gauge, measure the clearance between the drive and driven rotor tips.
Standard tip clearance: 0.025 - 0.085 mm (0.0010 - 0.0033 in.)Maximum tip clearance: 0.35 mm (0.0138
If the tip clearance is greater than maximum1 replace the rotors as a set.
C. Inspect rotor side clearance

Using a thickness gauge and precision straight edge, measure the clearance between the rotors and precision s
Standard side clearance: 0.025 - 0.085 mm (0.0010 - 0.0033 in.)Maximum side clearance: 0.10 mm (0.00
If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump as
3. REPLACE FRONT CRANKSHAFT OIL SEAL
OIL PUMP ASSEMBLY

1. INSTALL DRIVE AND DRIVEN ROTORS

(a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side.
(b) Install the oil pump body cover with the 5 screws. Torque: 10 N.m (105 kgf.cm, 8 ft.lbf)
2. INSTALL RELIEF VALVE
(a) Insert the relief valve. spring and retainer into the oil pump body hole.(b) Using snap ring pliers, install the sn
Oil Pump: Service and Repair

COMPONENTS FOR OIL PUMP REMOVAL AND INSTALLATION

OIL PUMP REMOVAL
HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned.
1. REMOVE HOOD2. DRAIN ENGINE OIL3. REMOVE ENGINE UNDER COVERS4. REMOVE TIMING BE
HINT: When removing the RH engine mounting, attach the engine hoist chain to the lifting bracket on the engine

5. REMOVE IDLER PULLEY AND TENSION SPRING
Remove the bolt. pulley and tension spring.
6. REMOVE CRANKSHAFT TIMING PULLEY
If the pulley cannot be removed by hand, use 2 screwdrivers.HINT: Position shop rags as shown to prevent dama
7. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK
(a) 7A-FE: Disconnect the crankshaft position sensor connector from the dipstick guide.(b) Remove the mountin
8. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.(b) Remove the 2 bolts holding the front exhaust pipe to the mountin
(d) Using a 14 mm deep socket wrench, remove the 2 nuts.(e) Remove the front exhaust pipe and 2 gaskets.
9. 4A-FE: REMOVE STIFFENER PLATE
(a) Remove the 5 set bolts.(b) Remove the stiffener plate.


10. REMOVE OIL PAN
(a) 4A-FE: Remove the 19 bolts, 2 nuts and oil pan.
(b) 7A-FE: Remove the 13 bolts, 2 nuts and No.2 oil pan.
(c) Insert the blade of SST between the cylinder block and oil pan, and cut off applied sealer and remove the oil
SST 09032-00100
NOTICE:
^ Do not use SST for the oil pump body side end rear oil seal retainer.^ Be careful not to damage the oil pan
11. 7A-FE: REMOVE OIL PAN BAFFLE PLATE
Remove 2 bolts, 2 nuts and baffle plate.
12. REMOVE OIL STRAINER

(a) 4A-FE: Remove the 2 bolts, 2 nuts, oil strainer and gasket.
(b) 7A-FE: Remove the 3 nuts, oil strainer and gasket.
13. 7A-FE: REMOVE NO.1 OIL PAN
(a) Remove the 3 transaxle mounting bolts from the engine rear end plate side.
(b) Remove the 6 bolts.(c) Using 5 mm hexagon wrench, remove the 14 bolts and No.1 oil pan.
(d) Remove the No.1 oil pan by prying the portions between the cylinder block and No.1 oil pan with a screwdriv

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan.
14. REMOVE OIL PUMP
(a) 7A-FE: Remove the bolt and crankshaft position sensor.(b) Remove the 7 bolts.
(c) Using a plastic-faced hammer. remove the oil pump by carefully tapping the oil pump body.(d) Remove the g
OIL PUMP INSTALLATION

1. INSTALL OIL PUMP
(a) Place a new gasket on the cylinder block.
(b) Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft. and slide the oil pum
(c) Install the oil pump with the 7 bolts.
Torque: 21 N.m (218 kgf.cm. 16 ft.lbf) Bolt length:
Long bolt: 35 mm (1.38 in.) Other bolt: 25 mm (0.98 in.)

(d) 7A-FE: Install the crankshaft position sensor with the bolt.
2. 7A-FE: INSTALL NO.1 OIL PAN

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surface
NOTICE: Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent^ Install a nozzle that has been cut to a 3 - 5 mm (0.12- 0.20
(c) Using a 5 mm hexagon wrench, install the No.1 oil pan with new 14 bolts. Torque the bolts.
Torque: 16 N.m (165 kgf.cm. 12 ft.lbf) for Bolt A
(d) Install the 6 bolts. Torque the bolts.
Torque: 7.8 N.m (80 kgf.cm. 69 in..lbf) for Bolt B
(e) Install and torque the 3 transaxle mounting bolts to the engine rear end plate side.
3. INSTALL OIL STRAINER

(a) 4A-FE: Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
(b) 7A-FE: Install a new gasket and the oil strainer with the 3 nuts.
4. 7A-FE: INSTALL OIL PAN BAFFLE PLATE
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)Install the baffle plate with the 2 bolts and nuts.
5. INSTALL OIL PAN (4A-FE)/NO.2 OIL PAN (7A- FE)

(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil
^ Using a razor blade and gasket scraper. remove all the old packing (FIPG) material from the gasket surface

^ Using a non-residue solvent. clean both sealing surfaces.
NOTICE: Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pan as shown in the illustration.
^ Install a nozzle that has been cut to a 3 - 5 mm (0.12- 0.20 in.) opening.^ Parts must be assembled within 5
(c) 4A-FE: Install the oil pan with the 19 bolts and 2 nuts.
(d) 7A-FE: Install the No.2 oil pan with the 1 3 bolts and 2 nuts.
6. 4A-FE: INSTALL STIFFENER PLATE

(a) Temporarily tighten the No.1 bolt.
(b) Torque the 5 bolts on the stiffener plate in the order shown.
7. INSTALL FRONT EXHAUST PIPE
(a) Place 2 new gaskets to the front and rear of the front exhaust pipe.(b) Using a 14 mm deep socket wrench. ins

(c) Install the 2 bolts and support bracket holding the front exhaust pipe to the TWC.
(d) Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket.
(e) Connect the oxygen sensor connector.
8. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
(a) Install a new O-ring to the dipstick guide.(b) Apply small amount of engine oil to the O-ring.(c) Push in the
(d) 7A-FE: Connect the crankshaft position sensor connector to the dipstick guide.
9. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the timing pulley set key with the key groove of the pulley.(b) Slide on the timing pulley, facing the fla
10. TEMPORARILY INSTALL IDLER PULLEY AND TENSION SPRING
(a) Install the idler pulley with the bolt. Do not tighten the bolt yet.(b) Install the tension spring.(c) Push the pull
11. INSTALL TIMING BELT12. FILL WITH ENGINE OIL13. START ENGINE AND CHECK FOR OIL LEAK
> Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: SpecificationsTorque Specifications

Camshaft Timing Pulley 43 ft.lb

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications
Timing Belt: SpecificationsService Specifications

Service Interval Replacement 60,000 miles
Timing Belt Deflection 5-6 mm

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Specifications > Page 976
Timing Belt: Testing and Inspection

INSPECT TIMING BELT
Do not bend,
NOTICE: - twist or turn the timing belt inside out.
- Do not allow the timing belt to come into contact with oil, water or steam.
- Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley
If there are any defects. as shown in the illustration, check the following points:
(a) Premature parting

- Check the proper installation.
- Check the timing cover gasket for damage and proper installation.
(b) If the belt teeth are cracked or damaged. check to see if either camshaft or water pump is locked.
(c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pull
(d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth. check the timing cover for damage. correct gasket installation, and
pulley teeth. If necessary, replace the timing belt.
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal
Timing Belt: Service and RepairTiming Belt Removal

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt > Component Information > Service and Repair > Timing Belt Removal > Page 979

TIMING BELT REMOVAL
1. Remove washer tank.
2. With Cruise Control System: Remove cruise control actuator.
3. Remove RH front wheel.
4. Remove RH engine under cover.
5. Loosen water pump pulley bolts and remove alternator drive belt.

(a) Stretch the belt tight and loosen the water pump pulley bolts.
(b) Loosen the pivot bolt and adjusting lock bolt.
(c) Loosen the adjusting bolt, and remove the drive belt.
6. With A/C: Remove A/C compressor without disconnecting hoses.
(a) Loosen the idler pulley mounting bolt A.
(b) Loosen the adjusting bolt B and remove the drive belt
(c) Disconnect the A/C compressor connector.
(d) Remove the 4 compressor mounting bolts.
(e) Move the compressor aside and suspend it.
7. With A/C: Remove A/C compressor mounting bracket.
8. With PS: Remove PS pump drive belt.

(a) Loosen the pivot and lock bolts.

(b) Swing PS pump toward the engine and remove the drive belt.
9. Disconnect connector from ground wire on RH fender apron.
10. Remove RH engine mounting insulator.
(a) Set the jack to the engine.
HINT: Place a wooden block between the jack and engine.
(b) With Cruise control system: Remove the 3 bolts, ground wire and actuator bracket.
(c) With A/C: Remove the screw, bolt and bracket.
(d) With A/C: Remove the bolt and damper.
(e) Remove the 5 bolts, 2 nuts and RH mounting insulator.
11. Remove water pump pulley.

12. Remove spark plugs.
13. Remove cylinder head cover.
(a) Disconnect the generator wire and clamp.
(b) Remove the 2 bolts and wiring harness protector.
(c) Disconnect the engine wire harness from the cylinder head.
(d) Disconnect the 2 PCV hoses from the cylinder head cover.

(e) Remove the 4 cap nuts, 4 seal washers, cylinder head cover and gasket.
14. Set No.1 Cylinder to TDC/Compression.
(360).
15. Remove No.3 and No.2 timing belt covers. Remove the 6 bolts and timing belt covers.
HINT (When re-using timing belt)
: Place matchmarks on the timing belt and camshaft timing pulley, and matchmarks on the timing belt tomatch th
16. Remove crankshaft pulley.

SST 09213-70010 and 09330-00021(a) Using , remove the pulley belt.
SST 09950-50010(09951 -05010,09952-05010. 09953-05020, 09954-05020)(b) Using . remove the pulley.
17. Remove no.1 timing belt cover. Remove the 3 bolts and timing belt cover.
18. Remove timing belt guide.

19. Remove timing belt.

Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks onthe tim

(a) Loosen the mounting bolt of the idler pulley and shift pulley toward the left as far as it will go and then tempo
(b) Remove the belt.
20. Remove idler pulley and tension spring.
21. Remove camshaft timing pulley. If the pulley cannot be removed by hand, use 2 screwdrivers.
NOTICE: Position shop rags as shown to prevent damage.
22. Remove camshaft timing pulley. Hold the hexagonal head wrench portion of the camshaft with a wrench, and rem
NOTICE: Be careful not to damage the cylinder head with the wrench.
Timing Belt: Service and RepairTiming Belt Installation


TIMING BELT INSTALLATION
1. Install camshaft timing pulley.

(a) Align the camshaft knock pin with the knock pin groove on the pulley side with "K" mark, and slide on the tim
(b) Temporarily install the timing pulley bolt.
(c) Hold the hexagonal wrench head portion of the camshaft with a wrench, and tighten the timing pulley bolt.
2. Install crankshaft timing pulley.
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the flange side inward.
3. Temporarily install idler pulley and tension spring.
(a) Install the idler pulley with the bolt. Do not tighten the bolt yet.
(b) Install the tension spring.

(c) Push the pulley toward the left as far as it will go and tighten the bolt.
4. Set No.1 cylinder to TDC/Compression.

(a) Turn the hexagonal wrench head portion of the camshaft, and align the hole of the camshaft timing pulley wit
cap.
(b) Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pull
5. Install timing belt.
(a) Install the timing belt on the crankshaft timing pulley.

Align the points marked during removal. and install the belt with the arrow pointing in the direction ofengine rev
(b) Install the timing belt guide, facing the cup side outward.
(c) Install the No.1 timing belt cover with the 3 bolts.
Torque: 7.4 N.m (75 kgf.cm, 65 in..lbf)
(d) Temporarily install the crankshaft pulley with the pulley bolt.

(e) Turn the crankshaft pulley, and align its groove with the timing mark 0 of the No.1 timing belt cover.
- Support the timing belt, so that the meshing of the crankshaft timing pulley and timing belt does not shift.
- Check that the matchmark on the timing belt matches the end of No.1 timing belt cover.
- Align the matchmarks of the timing belt and camshaft timing pulley.
(f) Install the timing belt, checking the tension between the crankshaft timing pulley and camshaft timing pulley.
6. Check valve timing and timing belt tension.
(a) Remove the grommet and loosen the timing belt idler pulley mounting bolt.
(b) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE: Always turn the crankshaft clockwise.


(c) Check that each pulley aligns with the marks as shown in the illustration. If the timing marks do not align, rem
it.
(d) Tighten the timing belt idler pulley mounting bolt.
(e) Install the grommet to the No.1 timing belt cover.
7. Reference:
Check timing belt deflection.Check that there is belt deflection at the position indicated in the illustration.
Belt deflection: 5 - 6 mm (0.20- 0.24 in.) at 20 N (2 kgf, 4.4 lbf)
If the deflection is not as specified, readjust with the idler pulley.
8. Install timing belt covers. Install the No.2 and No.3 timing belt covers with the 6 bolts.
9. Install crankshaft pulley.
(a) Align the pulley set key with the key groove of the pulley, and slide on the pulley.
SST 09213-70010,09330-00021(b) Using , install the pulley bolt.
Torque: 118 Nm (1,200 kgfcm, 87 ft.lbf)
10. Install cylinder head cover.

(d) Install the cylinder head cover with the 4 seal washers and 4 cap nuts. Uniformly tighten the cap nuts in sever
(e) Connect the 2 PCV hoses to the cylinder head cover.
(f) Install the engine wire harness and wiring harness protector with the 2 bolts.
(g) Connect the generator wire and clamp.
11. Install spark plugs.
12. Temporarily install water pump pulley.
13. Install RH engine mounting insulator.
(a) Install the mounting insulator with the 5 bolts and 2 nuts.
Torque:A: 64 N.m (650 kgf.cm, 47 ft.lbf)B: 52 N.m (530 kgf.cm, 38 ft.lbf)C: 25 N.m (260 kgf.cm, 19 ft.lb
(b) With A/C: Install the damper with the bolt.
(c) With A/C: Install the bracket with the bolt and screw.
(d) With Cruise control system: Install the actuator bracket and ground wire with the 3 bolts.
14. Connect ground connector to ground wire on RH fender apron.
15. With PS: Install and adjust PS drive belt.
16. With A/C: Install a/c compressor mounting bracket.
17. With A/C: Install a/c compressor.

18. With A/C: Install and adjust A/C drive belt.
19. Install and adjust generator drive belt.
Tighten the 4 water pump pulley bolts.
20. Install RH engine under cover.
21. Install RH front wheel.
22. With cruise control system: Install cruise control actuator.
23. Install washer tank.

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications
Timing Belt Tensioner: SpecificationsService Specifications

Installed Tension of Spring 34-38 N at 43.6 mm
Timing Belt Idler Pulley 27 ft.lb
Free Lenth of tension Spring 36.9 mm

> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Belt Tensioner > Component Information > Specifications > Page 996
Timing Belt Tensioner: Testing and Inspection

INSPECT IDLER PULLEY
Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.
INSPECT TENSION SPRING
(a) Measure the free length of tension spring.
Free length:4A-FE: 36.9 mm (1.453 in.)7A-FE: 31.8 mm (1.252 in.)

If the free length is not as specified. replace the tension spring.
(b) Measure the tension or the tension spring at the specified installed length.
Installed tension:4A-FE (at 43.6 mm (1.717 in.)):34 - 38 N (3.5 - 3.9 kgf, 7.7 - 8.6 lbf)7A-FE (at 37.6 mm
If the installed tension is not as specified. replace the tension spring.
> Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications
Timing Cover: SpecificationsTorque Specifications

Timing Belt Cover Bolts 7.4 Nm

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1004
HINT:
At Fusible link
- H-fuse (AM2 30A)
- EFI main relay
- Fuel pump
- Check that the
(-) terminal 12from

HINT:
-

-
Fuel hoses
is low, connections
- Fuel pump
- Fuel filter
- Start the engine.

(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)


- Stop the engine.
-

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis

Troubleshooting
Check
If the oxygen
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 1010

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom for Idle Speed: > NHT
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Recalls for Idle Speed: > NHTSA96
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for
Dec > 95 > Recall 96E001000: Defective Cruise Control Systems
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1029


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1030



> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1045





> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1046


> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications
Torque ..................................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 1050


Ignition Coil




Distributor

7. INSPECT AIR GAP
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)


DISTRIBUTOR REMOVAL





6. REMOVE CONDENSER
INSPECT SHAFT

NOTICE:




> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications

Recommended plugs
NGK BKR5EYA
Plug gap 0.031 in

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 1061

Torque .................................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1062





> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications

Std. ...................................................................................................................................................................................

At Idle Speed ....................................................................................................................................................................
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection
Chart > Page 1070

> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 107

Intake ........................................................................................................................................................................... 0.
> Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1072




(360).

-


NOTICE:


HINT:



Intake: N = T + (A - 0.20 mm (0.008 in.))
NOTICE:


NOTICE:

SST: 09248-55020 (09248-05011, 09248-05021)
HINT:
- Apply


Exhaust: N = T + (A - 0.30 mm (0.012 in.))


SST: 09248-55020 (09248-05011. 09248-05021)


> Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair
Water Pump: Service and Repair

> Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Page 1087

REMOVAL
1. Drain engine coolant.
2. Remove RH engine mounting insulator.3. Remove No. 2 and No. 3 timing belt covers.

4. Remove front engine mounting insulator as follows:
a. Remove the hole cover.b. Remove the 2 bolts from the mounting.c. Remove the nut, through-bolt and front eng
5. Remove electric cooling fan.6. Disconnect engine wire remove the bolt and 2 nuts, and disconnect the engine wire
a. Disconnect the crankshaft position sensor connector from the dipstick guide. b. Remove the mounting bolt and
e. Remove the 3 bolts and water pump.
CAUTION: Be careful not to get coolant on the timing belt.
INSTALLATION
1. Install water pump as follows:
14 Nm (10 ft. lbs.)
14.5 Nm (11 ft. lbs.)a. Place a new O-ring on the block.b. Install the pump with the 3 bolts. Torque the bolts to .c

d. Connect the water temperature sender gauge connector.
2. Install oil dipstick guide and dipstick as follows:
9.3 Nm (82 inch lbs.)

a. Install a new O-ring on the oil dipstick guide.b. Apply small amount of engine oil to the O-ring.c. Push in the o
3. Connect engine wire. Connect the engine wire with the bolt and 2 nuts.4. Install electric cooling fan.5. Install fron
87 Nm (64 ft. lbs.)
64 Nm (47 ft. lbs.)
a. Install the front engine mounting insulator, through-bolt and nut. Torque to .b. Install the 2 bolts to the mountin
6. Install No. 2 and No. 3 timing belt covers.7. Install RH engine mounting insulator.8. Fill radiator with engine cool
> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications
Coolant: Capacity Specifications
Capacity Manual Transmission Nippondenso radiator 5.8 qt (US)
Automatic Transmission Nippondenso Radiator 6.6 qt (US)
Coolant type Ethylene glycol

> Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 1095
Coolant: Fluid Type Specifications
Do not use alcohol type anti-freeze or water without anti-freeze.
Specified Type Ethylene-glycol Based Anti-freeze/coolant

Toyota brand recommended.
Coolant Concentration 50% Anti-freeze / 50% Distilled Or Demineralized Water

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations
Radiator Cooling Fan Motor: Component Locations
Junction Block and Wire Harness Connector
Junction Block And Wire Harness Connector

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations >
Page 1101

Page 1102

Page 1103

J/B No.3 Behind The Instrument Panel Center (Fig 24)
Page 1104

Parts Location
Parts Location
Page 1105

Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 28)
Page 1106

Page 1107

Position Of Parts In Instrument Panel (Part 1 Of 2) (Fig 30)
Page 1108

Relay Block
Relay Blocks
Page 1109

Service Hints
A10 A/C AMPLIFIER
1-Ground: 12 Volts ON LO, M1, M2 HIApprox. with the Ignition SW at position and blower SW at or pos
12 Volts ON ON
Always Continuity
5, 7-Ground: Approx. with the Ignition SW at position and A/C SW at position4-Ground:
9-Ground: 12 Volts ON LO, M1, M2 HI
ON Approx. with the Ignition SW at position and blower SW at or position and A/C SW at posit
B 6 BLOWER SW
3-7: LO, M1, M2 HIContinuity with the blower SW at or position
3-8: M1Continuity with the blower SW at position
3-6: M2continuity with the blower SW at position
3-5: HIContinuity with the blower SW at position
B 5 BLOWER SW
4-1: 2.7 OhmsApprox.
A 2 A/C TRIPLE PRESSURE SW (A/C DUAL AND SINGLE PRESSURE SW)

3-2: 13.5 kg/cm2 (1323 kPa, 191.7 psi)
10.0 kg/cm2 (980 kPa, 142 psi)Open above Approx. Closed below Approx.
1-4: 2.1 kg/cm2 (205.8 kPa, 29.8 psi) 27.0 kg/cm2 (2646 kPa, 383.4 psi)Open with pressure less than
W 2 WATER TEMP. SW
1-Ground:
90C (194F) 83C (181.4F)Open above Approx. Closed below Approx.
Splice Points
Page 1110

Splice Points
Location Of Splice Points (Fig 34)

Page 1111

System Outline
1. FAN MOTOR OPERATION
ON ECU-IG
--> TERMINAL 3 --> TERMINAL 2 --> TERMINAL 1 --> GROUND
ON
ECU-IG --> GROUND
ON CDS FANWhen the ignition SW is turned , current from the fuse flow radiator fan relay No. 1 (coil side) an
-
ON -->
--> GROUND ON
TERMINAL 2 --> TERMINAL 1 --> -->
--> TERMINAL 2 --> TERMINAL 1 --> GROUND
90C 194F 13.5 Kg/cm2 1323 kPa, 191.7 psi
ONLow Speed OperationWhen the ignition SW is turned and A/C is activated, current flows from the A/C m
-
13.5kg/cm2 1323 psi, 191.7 Kpa
OFF OFF
TERMINAL 2 --> TERMINAL 1 -->
--> --> GROUND
90C 194F
High Speed OperationWhen, during A/C operation, the Refrigerant pressure becomes higher than ordinary lev
2. SLOWER MOTOR OPERATION
-
ON LO GAUGE
-->TERMINAL 3 --> TERMINAL 7 --> GROUND ON
--> TERMINAL 1 --> TERMINAL 2 --> TERMINAL 4
--> TERMINAL 1 --> GROUNDLow Speed OperationWhen the ignition SW is turned and blower SW is se
-
ON M1 ON
HEATER --> TERMINAL 1 --> TERMINAL 2 --> TERMINAL 4
M2 --> TERMINAL 1
--> TERMINAL 2 --> TERMINAL 4 --> TERMINAL 2 --> TERMINAL 6
-->TERMINAL 7 --> GROUND
Medium Speed OperationWhen the ignition SW is turned and the blower SW is set to position, heater relay i
-
ON HI ON
-->TERMINAL 7 --> GROUND High Speed OperationWhen ignition SW is turned and the blower SW is s
3. AIR CONDITIONER OPERATION
ON GAUGE --> --> TERMINAL 3
-->TERMINAL 7 --> GROUND, --> A/C
--> TERMINAL 6 ON
ON
OFF
When the blower SW , current flows the fuse Heater relay (Coil Side) of the blower SW activating the heate
- LowA signal that the temperature at the Air outlet is
- High LowA signal that the refrigerant pressure is abnormally or

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations > Page 1112
Radiator Cooling Fan Motor: Connector Locations
Connector Joining Wire Harness And Wire Harness
Location Of Connector Joining Wire Harness And Wire Harness Ground Points (Fig 3
Page 1113

Location Of Connector Joining Wire Harness And Wire Harness (Fig 36)
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Component Locations > Page 1114
Radiator Cooling Fan Motor: Ground Locations
Ground Points
Page 1115

Location Of Ground Points (Fig 36)
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions

Ground Points
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Pa
Radiator Cooling Fan Motor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Radiator Fan And Air Conditioning-Connectors

Radiator Cooling Fan Motor: Electrical Diagrams

Radiator Fan And Air Conditioning (Part 1 Of 3)


> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 1136
Radiator Cooling Fan Motor: Description and Operation

1. FAN MOTOR OPERATION
ON ECU-IG
ON
ECU-IG --> GROUND
ON CDS FANWhen the ignition SW is turned , current from the fuse flow radiator fan relay No. 1 (coil side) an
-
ON -->
--> GROUND ON
TERMINAL 2 --> TERMINAL 1 --> -->
90C 194F 13.5 Kg/cm2 1323 kPa, 191.7 psi
ONLow Speed OperationWhen the ignition SW is turned and A/C is activated, current flows from the A/C m
-
13.5kg/cm2 1323 psi, 191.7 Kpa
OFF OFF
TERMINAL 2 --> TERMINAL 1 -->
--> --> GROUND
90C 194F
High Speed OperationWhen, during A/C operation, the Refrigerant pressure becomes higher than ordinary lev
2. SLOWER MOTOR OPERATION
-
ON LO GAUGE
-->TERMINAL 3 --> TERMINAL 7 --> GROUND ON
--> TERMINAL 1 --> GROUNDLow Speed OperationWhen the ignition SW is turned and blower SW is se
-
ON M1 ON
HEATER --> TERMINAL 1 --> TERMINAL 2 --> TERMINAL 4
M2 --> TERMINAL 1
--> TERMINAL 2 --> TERMINAL 4 --> TERMINAL 2 --> TERMINAL 6
-->TERMINAL 7 --> GROUND
Medium Speed OperationWhen the ignition SW is turned and the blower SW is set to position, heater relay i
-
ON HI ON
-->TERMINAL 7 --> GROUND High Speed OperationWhen ignition SW is turned and the blower SW is s
3. AIR CONDITIONER OPERATION
ON GAUGE --> --> TERMINAL 3
-->TERMINAL 7 --> GROUND, --> A/C
--> TERMINAL 6 ON
ON
OFF
When the blower SW , current flows the fuse Heater relay (Coil Side) of the blower SW activating the heate
- LowA signal that the temperature at the Air outlet is
- High LowA signal that the refrigerant pressure is abnormally or

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations

> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page 1140



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Locations
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagra
Instructions

Ground Points
> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION



> Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Location
> Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair
Heater Core: Service and Repair

No R&R for Heater Core in OE manual. Refer to Instrument Panel R&R.
> Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Cooling System - Radiator Cap Inspection Procedure
Radiator Cap: Technical Service BulletinsCooling System - Radiator Cap Inspection Procedure
ENGINEEG014-05
Title:RADIATOR CAP INSPECTION
Models:All Toyota Models
March 28, 2005
Introduction
The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspectin
Applicable Vehicles
^ All Toyota and Scion models.
Required Equipment
> Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Technical Service Bulletins > Cooling System - Radiator Cap Inspection
Procedure > Page 1180

Required SSTs
Radiator Cap Identification Procedure
1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating.
2. Proceed to the required inspection procedure for the radiator cap and kPa rating.
Radiator Cap Inspection Procedure
Type: N-cap, 88 kPa

1. Remove coolant and any foreign material on rubber points "A," "B," and "C."
2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen.
3. Check that points "C" and "D" are not stuck together.
4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.
Radiator Cap Tester:Snap-On/Sun P/N SVTS262A (or equivalent)

5.
Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kit
SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or09230-00050-01 (0923
6. When using the radiator cap tester, tilt it more than 30 degrees.
7. Pump the radiator cap tester several times, and check the maximum pressure.
Pumping speed: 1 pump/second
HINT:
Specification:
If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly.
Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed
Type: N-cap, 108 kPa

2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen.
3. Check that points "C" and "D" are not stuck together.
4. Apply engine coolant to points "B" and "C" before using the radiator cap tester.
Radiator Cap Tester:Snap-On/Sun P/N SVTS262A(or equivalent)
5.
SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or09230-00050-01(09231
HINT:
Specification:
Type: Compact Cap, 88 kPa

2. Check that points "A" and "B" are not deformed, cracked, or swollen.
3. Check that points "B" and "C" are not stuck together.
4. Apply engine coolant to point "B" before using the radiator cap tester.
5.
SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or09230-00050-01(09231
HINT:

Specification:
Type: Compact Cap, 108 kPa
2. Check that points "A" and "B" are not deformed, cracked, or swollen.
3. Check that points "B" and "C" are not stuck together.
4. Apply engine coolant to point "B" before using the radiator cap tester.
5.
SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or09230-00050-01 (0923


HINT:
Specification:
Type: Plastic Cap, 108 kPa
1. Remove coolant and any foreign material on 0-ring "A."
2. Check that 0-ring "A" is not deformed, cracked, or swollen.
3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester.

4.
^
SST P/N 09230-00030-01(09231-10080-01) or09230-00020-01 (09231-10060-01) or09230-00050-01(09231-

HINT:
Specification:
> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations

> Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations > Page
1191

1192

1193

Details
1194

Body (Fig 19)
1195

Body (Fig 19)
Locations
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Com
Diagrams > Diagram Information and Instructions

Ground Points
> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/
Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1202

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Diagrams > Page 1217

CIRCUIT DESCRIPTION



> Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Sw
Locations
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications
Thermostat: Mechanical Specifications

[1]Valve Lift .......................................................................................................................................................................
[1] At 95 C (203 F)
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Mechanical Specifications > Page 1226
Thermostat: Pressure, Vacuum and Temperature Specifications

Opening Temperature ..........................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 1227
Thermostat: Testing and Inspection
NOTE: The thermostat is numbered with the valve opening temperature.
80-84C (176-183F)1. Immerse the thermostat in water and gradually heat the water.2. Check the valve opening temp
replace the thermostat.
8 mm (0.31 inch) 95C (203F)

40C (104F)3. Check the valve lift. Valve lift: or more at . If the valve lift is not as specified, replace the thermostat.4
Thermostat: Service and Repair
CAUTION:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the
REMOVAL
1. Drain engine coolant
(ECT)
2. Disconnect Engine Coolant Temperature switch connector.3. Remove water inlet and thermostat as follows:
a. Remove the 2 nuts and water inlet from the water inlet housing.b. Remove the thermostat.c. Remove the gaske
INSTALLATION

1. Place thermostat in water inlet housing as follows:
a. Install a new gasket onto the thermostat.b. Align the thermostat jiggle valve with the upper side of the stud bol
NOTE: The jiggle valve may be set within 10 of either side of the prescribed position.
2. Install water inlet. Install the water inlet with the 2 nuts. Torque to.3. Connect ECT switch connector.4. Fill radiato
> Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications
Thermostat Housing: Specifications

Bolts .....................................................................................................................................................................................
> Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair
Water Pump: Service and Repair

> Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Page 1237

REMOVAL
1. Drain engine coolant.
2. Remove RH engine mounting insulator.3. Remove No. 2 and No. 3 timing belt covers.

4. Remove front engine mounting insulator as follows:
a. Remove the hole cover.b. Remove the 2 bolts from the mounting.c. Remove the nut, through-bolt and front eng
5. Remove electric cooling fan.6. Disconnect engine wire remove the bolt and 2 nuts, and disconnect the engine wire
a. Disconnect the crankshaft position sensor connector from the dipstick guide. b. Remove the mounting bolt and
e. Remove the 3 bolts and water pump.
CAUTION: Be careful not to get coolant on the timing belt.
INSTALLATION
1. Install water pump as follows:
14 Nm (10 ft. lbs.)
14.5 Nm (11 ft. lbs.)a. Place a new O-ring on the block.b. Install the pump with the 3 bolts. Torque the bolts to .c

d. Connect the water temperature sender gauge connector.
2. Install oil dipstick guide and dipstick as follows:

a. Install a new O-ring on the oil dipstick guide.b. Apply small amount of engine oil to the O-ring.c. Push in the o
3. Connect engine wire. Connect the engine wire with the bolt and 2 nuts.4. Install electric cooling fan.5. Install fron
87 Nm (64 ft. lbs.)
64 Nm (47 ft. lbs.)
a. Install the front engine mounting insulator, through-bolt and nut. Torque to .b. Install the 2 bolts to the mountin
6. Install No. 2 and No. 3 timing belt covers.7. Install RH engine mounting insulator.8. Fill radiator with engine cool
> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications
Catalytic Converter: Specifications

Torque ..................................................................................................................................................................................
> Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Specifications > Page 1244
Catalytic Converter: Testing and Inspection

TWC INSPECTION
CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it touches the converter, repair or replace it
-
HEAT INSULATOR INSPECTION
1. CHECK HEAT INSULATOR FOR DAMAGE2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATA
Catalytic Converter: Service and Repair
TWC REPLACEMENT
1. REMOVE TWC
- Jack up the vehicle.
- Check that the converter is cool.
- Remove the 4 bolts, support bracket and 2 nuts at the front and rear of the converter.
- Remove the converter and 2 gaskets.
2. REINSTALL CONVERTER
- Install the converter and 2 new gaskets with the 4 bolts, 2 nuts and support bracket.
- Tighten the bolts and nuts.

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications
Exhaust Manifold: Specifications
Exhaust Manifold X Cylinder HeadTorque .........................................................................................................................

> Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 1250
Exhaust Manifold: Service and Repair

NOTE: On models with coded audio anti-theft systems, Technician Safety Information refer to for code procedur
1. On models with air bag system, Technician Safety Information. disarm airbag system as outlined under
2. Disconnect battery ground cable.
3. Remove exhaust pipe from exhaust manifold.
4. Disconnect all electrical connectors, hoses, cables, fuel lines and electrical equipment that will interfere with rem
5. Remove manifold stay, then insulator.
6. Remove exhaust manifold attaching bolts, then exhaust manifold, insulators and gasket.
7. 25 ft. lb.Reverse procedure to install. Torque bolts to
8. On models with air bag system, Technician Safety Information.
Technician Safety Information rearm airbag system as outlined under If audio system was disabled, activateas
> Hybrid Drive Systems > Battery System, Hybrid Drive > System Information > Technical Service Bulletins > Electrical - SRS And HV Wiring Repairs
Battery System, Hybrid Drive: Technical Service BulletinsElectrical - SRS And HV Wiring Repairs
TITLE: SRS & HV WIRING REPAIRS
SECTION: ELECTRICAL
BULLETIN # 156
MODELS: ALL TOYOTA LEXUS and SCION MODELS
DATE: AUGUST 2007
There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SR
If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information >
Page 1263

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component
Information > Locations > Component Locations > Page 1264

Instructions

Ground Points

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON


Module Pinout Values


Module Pinout Values > Page 1286

CIRCUIT DESCRIPTION
WIRING DIAGRAM


> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel Sy
Locations

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel Sy




> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel Pump Relay] > Com
Inspection




> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel
Pump Relay] > Component Information > Testing and Inspection > Page 1303

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel Sy
Locations

> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel Sy




> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Informatio
and Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Compute

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch
(For Computer) > Component Information > Diagrams > Diagram Information and Instructions > Page 1340

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION



> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft
Information > Specifications > Electrical Specifications

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
Information > Specifications > Electrical Specifications > Page 1361

Torque ..................................................................................................................................................................................
Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--
> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1364

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION





> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Infor

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
CIRCUIT DESCRIPTION


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component I

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor
> Component Information > Diagrams > Diagram Information and Instructions > Page 1407

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
CIRCUIT DESCRIPTION


Voltage drop:

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Techn
Controls - Bank 1/Bank 2 O2 Sensor identification
ENGINEEG034-07
June 28, 2007
Introduction
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component

Applicable Vehicles



Controls - Bank 1/Bank 2 O2 Sensor identification > Page 1432
December 17, 2003
Introduction
All 1996Vehicles^

Required SSTs
NOTE:

HINT:
^ DIAGNOSTICS
^ CARB OBD II

^ O2S TEST RESULTS
NOTE:
3.
Example:

17 x 0.3906 = 6.6%
NOTE:
NOTE:







CHART 1

CHART 2
CHART 3
CHART 4

CHART 5
CHART 6

CHART 7

CHART 8
CHART 9

CHART 10

CHART 11

CHART 12
CHART 13

CHART 14

CHART 15

CHART 16
CHART 17

CHART 18
CHART 19

CHART 20


CHART 21

CHART 22


CHART 23


CHART 24

CHART 25


CHART 26


CHART 27


CHART 28

CHART 29

CHART 30

> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagra
Instructions

Ground Points

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
CIRCUIT DESCRIPTION


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information
and Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Comp

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 1515

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
1530

CIRCUIT DESCRIPTION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >

Torque ..................................................................................................................................................................................
Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information
and Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams >

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information
> Diagrams > Diagram Information and Instructions > Page 1576

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Page 1580



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Page 1590

CIRCUIT DESCRIPTION
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor]

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................

Torque ..................................................................................................................................................................................
> Diagram Information and Instructions

Ground Points
> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Page 1614

CIRCUIT DESCRIPTION
> Page 1615



> Page 1616


> Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair
> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications


> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1624
HINT:
At Fusible link
- H-fuse (AM2 30A)
- EFI main relay
- Fuel pump
- Check that the
(-) terminal 12from

HINT:
-

-
Fuel hoses
is low, connections
- Fuel pump
- Fuel filter
- Start the engine.

(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)


- Stop the engine.
-

> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis

Troubleshooting
Check
If the oxygen
> Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > System Diagnosis > Page 1630

> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Recalls for Idle Speed: > NHTSA96E001000 > De
Defective Cruise Control Systems
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > By Symptom for Idle Speed: > NHTSA96E00100
Defective Cruise Control Systems
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > N
Recall 96E001000: Defective Cruise Control Systems
> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1649


> Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1650



> Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications

> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1665





> Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Specifications > Page 1666


> Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications
Torque ..................................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Specifications > Page 1670


Ignition Coil




Distributor

7. INSPECT AIR GAP
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)


DISTRIBUTOR REMOVAL





6. REMOVE CONDENSER
INSPECT SHAFT

NOTICE:




> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications

Recommended plugs
NGK BKR5EYA
Plug gap 0.031 in

> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 1681

Torque .................................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1682





> Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications

Std. ...................................................................................................................................................................................

At Idle Speed ....................................................................................................................................................................
> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart

> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page
1690

> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Adjusting Shim Selection Chart > Page 1691

Intake ........................................................................................................................................................................... 0.
> Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1692




(360).

-


NOTICE:


HINT:



Intake: N = T + (A - 0.20 mm (0.008 in.))
NOTICE:


NOTICE:

SST: 09248-55020 (09248-05011, 09248-05021)
HINT:
- Apply


Exhaust: N = T + (A - 0.30 mm (0.012 in.))


SST: 09248-55020 (09248-05011. 09248-05021)


> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions
A/C Signal: Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Diagram Information and Instructions > Page 1709

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
A/C Signal: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > A/C Signal > Component Information > Diagrams > Page 1724
A/C Signal: Description and Operation

A/C Cut Control Circuit
CIRCUIT DESCRIPTION
This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration performan
A/C Signal: Testing and Inspection

A/C Cut Control Circuit
CIRCUIT DESCRIPTION
This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration performan
DETECTING CONDITION
WIRING DIAGRAM

TOYOTA hand-held tester
OBD II scan tool (excluding TOYOTA hand-held tester)

> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Page 1731

Power Source
Key to Diagrams
> Page 1732

Power Window
> Page 1733

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
> Page 1734

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1735
> Page 1736

> Page 1737

> Page 1738

Special Tool

> Page 1739

HINT:
"Case 1"
"Case 2"

: Connector Body
> Page 1740

"Case 1"
HINT:
"Case 2"
> Page 1741

Terminal Retainer
Locking Lug

HINT:
> Page 1742


> Page 1743

CAUTION:
Voltage Check
ON
> Page 1744

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1745
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 1746
CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagrams > Page 1747


> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 1752

Power Source
Key to Diagrams
Page 1753

Power Window
Page 1754

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
Page 1755

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1756
Page 1757

Page 1758

Page 1759

Special Tool

Page 1760

HINT:
"Case 1"
"Case 2"

: Connector Body
Page 1761

"Case 1"
HINT:
"Case 2"
Page 1762

Terminal Retainer
Locking Lug

HINT:
Page 1763


Page 1764

CAUTION:
Voltage Check
ON
Page 1765

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1766
> Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 1767

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram Information and Instr

Ground Points
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Diagram

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1787

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Page 1788



> Powertrain Management > Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Specifications > Electrical Sp

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Specifications > Electrical Sp

Torque ..................................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Inform

Ground Points
> Powertrain Management > Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 1811

CIRCUIT DESCRIPTION





> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page
1818

Power Source
Key to Diagrams
1819

Power Window
1820

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
1821

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 1822
Data Link Connector: Diagnostic Aids
1823

1824

1825

Special Tool

1826

HINT:
"Case 1"
"Case 2"

: Connector Body
1827

"Case 1"
HINT:
"Case 2"
1828

Terminal Retainer
Locking Lug

HINT:
1829


1830

CAUTION:
Voltage Check
ON
1831

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 1832
Data Link Connector: Testing and Inspection
DATA LINK CONNECTOR 3 (DLC3) INSPECTION
The vehicle's ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The term
HINT:
If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable of the OB
Service Department listed in the tool's instruction manual.
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 1837

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Component Locations > Page 1838

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page
1841

Power Source
Key to Diagrams
1842

Power Window
1843

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
1844

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1845
1846

1847

1848

Special Tool

1849

HINT:
"Case 1"
"Case 2"

: Connector Body
1850

"Case 1"
HINT:
"Case 2"
1851

Terminal Retainer
Locking Lug

HINT:
1852


1853

CAUTION:
Voltage Check
ON
1854

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1855

1856

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Control Module Pinout Values

> Page 1859

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Control Module Pinout Values > Page 1860

CIRCUIT DESCRIPTION
WIRING DIAGRAM
> Page 1861

> Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Page 1862

> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Component Inspection
Idle Speed/Throttle Actuator - Electronic: Testing and InspectionComponent Inspection
IAC VALVE INSPECTION

INSPECT IAC VALVE OPERATION
Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check
-- Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check
- If operation is not as specified, replace the IAC valve.
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Component Inspection > Page
Idle Speed/Throttle Actuator - Electronic: Testing and InspectionOn-Vehicle Inspection

1. INSPECT IAC VALVE OPERATION
-
Engine
Initial at normal operating temperature
conditions:-
- Idle speed set correctly
- Transmission in neutral
-
Using SST, connect terminals TE1 and E1 of the DLC1.SST 09843-18020
-
After engine speed are kept at 900 - 1,300 rpm for 5 seconds, check that they return to idle speed. If the rpm o
- Remove the SST from the DLC1. SST 09843-18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE: "Cold" and "Hot" in those sentences express the temperature of the coils themselves."Cold" is
- Disconnect the IAC valve connector.
- Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO).
Resistance:Cold: 17.0 - 24.5 ohmHot: 21.5 - 28.5 ohm

- If resistance is not as specified, replace the IAC valve.
- Reconnect the IAC valve connector.
> Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Page 1868
Idle Speed/Throttle Actuator - Electronic: Service and Repair
IAC VALVE REMOVAL
1. REMOVE THROTTLE BODY2. REMOVE IAC VALVE

- Remove the 4 screws, IAC valve and gasket.
INSTALLATION HINT: Place a new gasket on the throttle body.

> Powertrain Management > Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations

> Powertrain Management > Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page
1872

1873

1874

Details
1875

Body (Fig 19)
1876

Body (Fig 19)
Locations
> Powertrain Management > Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 1877



1878

> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 18



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 18
> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1898
CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Diagrams > Page 1899


Voltage drop:

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bank 1/Bank 2 O2 Sensor identi
ENGINEEG034-07
June 28, 2007
Introduction
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bank 1/Bank 2
O2 Sensor identification > Page 1904

Applicable Vehicles



> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bank 1/Bank 2 O2 Sensor identi
December 17, 2003
Introduction
All 1996Vehicles^

Required SSTs
NOTE:

HINT:
^ DIAGNOSTICS
^ CARB OBD II

^ O2S TEST RESULTS
NOTE:
3.
Example:

17 x 0.3906 = 6.6%
NOTE:
NOTE:







CHART 1

CHART 2
CHART 3
CHART 4

CHART 5
CHART 6

CHART 7

CHART 8
CHART 9

CHART 10

CHART 11

CHART 12
CHART 13

CHART 14

CHART 15

CHART 16
CHART 17

CHART 18
CHART 19

CHART 20


CHART 21

CHART 22


CHART 23


CHART 24

CHART 25


CHART 26


CHART 27


CHART 28

CHART 29

CHART 30
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1946

> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 1947
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1950

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1965
CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1966


> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Co
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Co

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information >
Locations > Component Locations > Page 1973

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Di

Ground Points

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Page 1980



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Page 1990


> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Ins
Values

Testing and Inspection > Control Module Pinout Values > Page 1994

Values > Page 1995

CIRCUIT DESCRIPTION
WIRING DIAGRAM
Testing and Inspection > Control Module Pinout Values > Page 1996


> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Com

> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel
System)] > Component Information > Locations > Page 2001



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Com
Page 2006




> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams >

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Page 2017



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Page 2027

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer
) > Component Information > Diagrams > Diagram Information and Instructions > Page 2033

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION



> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor]

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................

Torque ..................................................................................................................................................................................

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Engine RPM Sensor (NE signal) <--> [Crankshaft

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION





> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Diagra
Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
CIRCUIT DESCRIPTION


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Di
Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
CIRCUIT DESCRIPTION


Voltage drop:

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bul
Bank 2 O2 Sensor identification
ENGINEEG034-07
June 28, 2007
Introduction
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information >
Technical Service Bulletins > Engine Controls - Bank 1/Bank 2 O2 Sensor identification > Page 2121

Applicable Vehicles



Bank 2 O2 Sensor identification > Page 2125
December 17, 2003
Introduction
All 1996Vehicles^

Required SSTs
NOTE:

HINT:
^ DIAGNOSTICS
^ CARB OBD II

^ O2S TEST RESULTS
NOTE:
3.
Example:

17 x 0.3906 = 6.6%
NOTE:
NOTE:







CHART 1

CHART 2
CHART 3
CHART 4

CHART 5
CHART 6

CHART 7

CHART 8
CHART 9

CHART 10

CHART 11

CHART 12
CHART 13

CHART 14

CHART 15

CHART 16
CHART 17

CHART 18
CHART 19

CHART 20


CHART 21

CHART 22


CHART 23


CHART 24

CHART 25


CHART 26


CHART 27


CHART 28

CHART 29

CHART 30

> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram

Ground Points

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
2171



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
2181
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2182
CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2183


> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > D

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Page 2192



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Page 2202
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > P

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Informati
and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications

Torque ..................................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Dia

Ground Points
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Dia
Page 2233



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2247

Power Source
Key to Diagrams
Page 2248

Power Window
Page 2249

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
Page 2250

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2251
Page 2252

Page 2253

Page 2254

Special Tool

Page 2255

HINT:
"Case 1"
"Case 2"

: Connector Body
Page 2256

"Case 1"
HINT:
"Case 2"
Page 2257

Terminal Retainer
Locking Lug

HINT:
Page 2258


Page 2259

CAUTION:
Voltage Check
ON
Page 2260

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2261
> Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Diagrams > Page 2262

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > P



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > P
> Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2282

CIRCUIT DESCRIPTION
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications

Torque ..................................................................................................................................................................................
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page
2288

Power Source
Key to Diagrams
2289

Power Window
2290

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
2291

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2292
2293

2294

2295

Special Tool

2296

HINT:
"Case 1"
"Case 2"

: Connector Body
2297

"Case 1"
HINT:
"Case 2"
2298

Terminal Retainer
Locking Lug

HINT:
2299


2300

CAUTION:
Voltage Check
ON
2301

Voltage Check
ON
> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications
Catalytic Converter: Specifications

Torque ..................................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Specifications > Page 2306
Catalytic Converter: Testing and Inspection

TWC INSPECTION
CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it touches the converter, repair or replace it
-
HEAT INSULATOR INSPECTION
1. CHECK HEAT INSULATOR FOR DAMAGE2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATA
Catalytic Converter: Service and Repair
TWC REPLACEMENT
1. REMOVE TWC
- Jack up the vehicle.
- Check that the converter is cool.
- Remove the 4 bolts, support bracket and 2 nuts at the front and rear of the converter.
- Remove the converter and 2 gaskets.
2. REINSTALL CONVERTER
- Install the converter and 2 new gaskets with the 4 bolts, 2 nuts and support bracket.
- Tighten the bolts and nuts.

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Testing and Inspection
Evaporative Emission Control Canister: Testing and Inspection
CHARCOAL CANISTER INSPECTION
1. REMOVE CHARCOAL CANISTER2. REMOVE CAP FROM CHARCOAL CANISTER3. VISUALLY INSPEC
- Look for cracks or damage.
4. INSPECT FOR CLOGGED FILTER AND STUCK CHECK VALVE
-
Blow low pressure compressed air (4.71 kPa, 48 kgf/ sq.cm, 0.68 psi), into port A and check that air flows wi
- Blow low pressure compressed air into port B and check that air does not flow from the other ports.
- If a problem is found, replace the charcoal canister.
5. CLEAN FILTER IN CANISTER
- Clean the filter by blowing 294 kPa (3 kgf/sq.cm, 43 psi) of compressed air into port A while holding port B c
NOTICE:
- Do not attempt to wash the canister.
- No activated carbon should come out.
6. REINSTALL CAP TO CHARCOAL CANISTER7. REINSTALL CHARCOAL CANISTER

> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Testing and Inspection
Thermal Vacuum Valve - EVAP: Testing and Inspection
TVV INSPECTION
1. DRAIN ENGINE COOLANT2. REMOVE TVV FROM WATER INLET HOUSING

-
Disconnect the following hoses:(1) Vacuum hose (from charcoal canister)(2) Vacuum hose (from throttle bod
- Remove the TVV.
3. INSPECT TVV OPERATION
- Cool the TVV to below 35 C (95F) with cool water.
- Check that air does not flow from the upper port to lower port.
- Heat the TVV to above 54 C (129F) with hot water.
- Check that air flows from the upper port to lower port.
- If operation is not as specified, replace the TVV.
4. REINSTALL TVV
- Apply adhesive to 2 or 3 threads of the TVV, and install it.
Adhesive:Part No. 08S33-00070, THREE BOND 1324 or equivalent
> Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Testing and
Inspection > Page 2316

- Reconnect 2 vacuum hoses.

5. REFILL WITH ENGINE COOLANT
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications
EGR Valve: Specifications

Torque ..................................................................................................................................................................................
> Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 2321
EGR Valve: Testing and Inspection
EGR SYSTEM INSPECTION

1. INSPECT AND CLEAN FILTER IN EGR VACUUM MODULATOR
- Remove the cap and filter.
- Check the filter for contamination or damage.
- Using compressed air, clean the filter.
- Reinstall the filter and cap.
HINT: Install the filter with the coarser surface facing the atmospheric side (outward).
2. INSTALL VACUUM GAUGE

- Using a 3-way connector, connect a vacuum gauge to the hose between EGR valve and VSV.
3. INSPECT SEATING OF EGR VALVE
- Start the engine and check that the engine starts and runs at idle.
4. CONNECT TERMINALS TE1 AND E1 OF DATA LINK CONNECTOR 1

- Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843-18020
5. INSPECT VSV OPERATION WITH COLD ENGINE
- The engine coolant temperature should be below 47 C (117 F).
6. INSPECT
- CheckOPERATION
that the vacuum
OFgauge
VSV indicates
AND EGR zero
VACUUM
at 2,500 rpm.
MODULATOR WITH HOT ENGINE
- Warm up the engine to above 53 C (127 F).
- Check that the vacuum gauge indicates low vacuum at 2,500 rpm.

- Disconnect the vacuum hose from port R of the EGR vacuum modulator and connect port R directly to the int
- Check that the vacuum gauge indicates high vacuum at 2,500 rpm.
HINT: As a large amount of exhaust gas enters, the engine will misfire slightly.
7. REMOVE VACUUM GAUGE

- Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations.
8. INSPECT EGR VALVE

- Apply vacuum directly to the EGR valve with the engine idling.
- Check that the engine runs rough or dies.
- Reconnect the vacuum hoses to the proper locations.
9. REMOVE SST FROM DATA LINK CONNECTOR 1. SST 09843-18020
IF NO PROBLEM IS FOUND WITH THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT E
VSV INSPECTION
1. REMOVE VSV
2. INSPECT VSVA. Inspect VSV for open circuit
- Using an ohmmeter, check that there is continuity between the terminals.
Resistance: At 20 C (68F): 37 - 44 ohm
- If there is no continuity, replace the VSV.

B. Inspect VSV for ground
- Using an ohmmeter, check that there is no continuity between each terminal and the body.
- If there is continuity, replace the VSV.
C. Inspect VSV operation

- Check that air flows from port E to the filter.
- Apply battery voltage across the terminals.
- Check that air flows from port E to port F.

- If operation is not as specified, replace the VSV.
3. REINSTALL VSV
EGR VACUUM MODULATOR INSPECTION

INSPECT EGR VACUUM MODULATOR OPERATION
Disconnect the vacuum hoses from ports P, Q and R of the EGR vacuum modulator.
-- Block ports P and R with your finger.
- Blow air into port Q, and check that the air passes through to the air filter side freely.
- Start the engine, and maintain speed at 2,500 rpm.
- Repeat the above test. Check that there is a strong resistance to air flow.
- Reconnect the vacuum hoses to the proper locations.
EGR Valve: Service and Repair
COMPONENTS FOR EGR VALVE REMOVAL AND INSTALLATION
1. REMOVE
EGR AIR CLEANER HOSE AND CAP
VALVE REMOVAL
(See cylinder head removal)
2. REMOVE EGR VALVE

-
Vacuumthe
Disconnect hose
following hoses and connector:-
- EGR hose
- EGR gas temp. sensor connector
- Remove the 2 nuts, EGR valve and gasket.
INSTALLATION HINT: Install the EGR valve with a new gasket.

EGR VALVE INSPECTION
INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
-- If a problem is found, replace the valve.
EGR VALVE INSTALLATION

> Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Testing and Inspection
Positive Crankcase Ventilation: Testing and Inspection
PCV VALVE INSPECTION
1. REMOVE PCV VALVE2. INSTALL CLEAN HOSE TO PCV VALVE3. INSPECT PCV VALVE OPERATION
- Blow air into the cylinder head side, and check that air passes through easily.
CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful
- Blow air into the intake manifold side, and check that air passes through with difficulty.
- If operation is not as specified, replace the PCV valve.
4. REMOVE CLEAN HOSE FROM PCV VALVE5. REINSTALL PCV VALVE
PCV HOSES AND CONNECTIONS INSPECTION

VISUALLY INSPECT HOSES AND CONNECTIONS
Check for cracks, leaks or damage.
-
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications


> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 2333
HINT:
At Fusible link
- H-fuse (AM2 30A)
- EFI main relay
- Fuel pump
- Check that the
(-) terminal 12from

HINT:
-

-
Fuel hoses
is low, connections
- Fuel pump
- Fuel filter
- Start the engine.

(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)


- Stop the engine.
-

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > By Symptom for Idle Speed: > NHTSA96E001000 > Dec >
Cruise Control Systems
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Recalls for Idle Speed: > NHTSA96E001000 > Dec > 95 >
Control Systems
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > NHTSA96
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 2357


> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 2358



> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > System Diagnosis

Troubleshooting
Check
If the oxygen
> Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System Information > System Diagnosis > Page 2362

> Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Exhaust System - Sulfur Smell
Fuel: Technical Service BulletinsExhaust System - Sulfur Smell
ENGINEEG003-03
February 24, 2003
Title:SULFUR ODOR FROM EXHAUST
Models:All Models
Introduction
Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a
Applicable Vehicles
^ All Models.
Repair Procedure
A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's run
^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed:
^ If the MIL light is ON, check for DTCs and repair as necessary.
If no trouble is found after performing the above check, recommend the customer try a different source of fuel.
Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair

Union Bolt Type:

-

Flare Nut Type:

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Cleaning Procedure
Fuel Injector: Technical Service BulletinsFuel System - Fuel Injector Cleaning Procedure
PRODUCT GENERAL INFORMATIONPG011-05REVISED

October 13, 2005
Title:FUEL INJECTOR CLEANING
Models:'90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection
TSB REVISION NOTICE:

^
June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device a
Introduction
Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogg
All 1990Vehicles:^
Applicable - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI).
Required Tools & Material
Repair Procedure
1.
If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, comp
A.
Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyot
^ Idle air control device
^ Throttle plate (both sides if possible)
^ Throttle body
B. Bring the engine to operating temperature.
C. Disconnect the fuel pump electrical connector.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Cleaning

D. Start the engine. After the engine has stalled, turn the ignition switch OFF.
E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if app
NOTE:
Do NOT clamp plastic lines.
F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose.
G.
Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can o
H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls.
I. Turn the ball valve OFF and remove the empty can.
J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system.
K.
Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel l
L. Before starting the vehicle, pressurize the fuel system and check for leaks.
Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may re
2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel
3. Road test the vehicle to verify normal operation.

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Page 2376
Fuel Injector: Specifications

Resistance ......................................................................................................................................................................... A
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Injection Inspection
Fuel Injector: Testing and InspectionInjection Inspection

INJECTORS INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION: Keep injector away from sparks during the test.
- Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet.
- Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolt. SST 09268-41045 (90

- Remove the pressure regulator from the delivery pipe.
- Install the O-ring to the fuel inlet of the pressure regulator.
- Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Injection Inspection > Page 2379

- Connect the fuel return hose to the fuel outlet of the pressure regulator.
- Install the grommet and O-ring to the injector.
- Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-4
- Put the injector into the graduated cylinder.
HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out.
-
- Reconnect negative (-) terminal cable to the battery.
-
Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a gradu
Volume: 39 - 49 cu.cm (2.4 - 3.0 cu in.) per 15 secs.
Difference between each injector: 5 cu.cm (0.3 cu in.) or less

- If the injection volume is not as specified, replace the injector.

2. INSPECT LEAKAGE
-
In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage fr
Fuel drop: One drop or less per minute

- Disconnect the negative (-) terminal cable from the battery.
- Remove the SST. SST 09268-41045,09843-18020
- Reinstall the fuel inlet hose to the fuel filter outlet with 2 new gaskets and the union bolt.

Fuel Injector: Testing and InspectionOn-Vehicle
1. INSPECT INJECTOR OPERATION
- Check operation sound from each injector.
- With the engine running or cranking, use a sound scope to check that there is normal operating noise in propo
- If you have no sound scope. you can check the injector transmission operation with your finger.
- If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM.
2. INSPECT INJECTOR RESISTANCE
- Disconnect the injector connector.
Resistance: At 20 C (68 F): 13.4 - 14.2 ohm
- If the resistance is not as specified, replace the injector.

- Reconnect the injector connector.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Page 2382
Fuel Injector: Service and Repair

INJECTORS REMOVAL

1. REMOVE AIR CLEANER HOSE AND CAP2. DISCONNECT THROTTLE BODY AND AIR INTAKE CHAM
-
Disconnect these the hoses and connectors:(1) 2 PCV hoses from cylinder head cover(2) Vacuum sensing hos
(3) EGR hose from EGR valve(4) Vacuum hose from EGR valve(5) VSV (for EGR) connector
-
Using a 6 mm hexagon wrench, remove the 3 bolts and 2 nuts, and disconnect the throttle body and chamber c
3. DISCONNECT INJECTOR CONNECTORS
4. DISCONNECT FUEL INLET HOSE FROM DELIVERY PIPE

- Remove the union bolt and 2 gasket, and disconnect the inlet hose from the delivery pipe.
HINT:
- Put a suitable
Slowly loosencontainer
the unionorbolt.
shop towel under the delivery pipe.
-
5. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR

6. REMOVE DELIVERY PIPE AND INJECTORS
- Remove the 2 bolts and delivery pipe together with the 4 injectors.
NOTICE: Be careful not to drop the injectors when removing the delivery pipe.
- Remove the 4 insulators and 2 spacers from the intake manifold.

- Pull out the 4 injectors from the delivery pipe.
- Remove the O-ring and grommet from each injector.
INJECTORS INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE

- Install a new grommet to the injector.
- Apply a light coat of gasoline to a new O-ring and install it to the injector.
- While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors.
- Position the injector connector upward.
- Place 4 new insulators and the 2 spacers in position on the intake manifold.

- Place the 4 injectors and delivery pipe assembly in position on the intake manifold.
- Temporarily install the 2 bolts holding the delivery pipe to the intake manifold.
- Check that the injectors rotate smoothly.
HINT: If the injectors do not rotate smoothly, the probable cause is in correct installation of the O-rings. Rep
- Position the injector connector upward.
- Tighten the 2 bolts holding the delivery pipe to the intake manifold.

2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR3. CONNECT FUEL INLET HOSE T
- Connect the inlet hose with 2 new gaskets and the union bolt.
4. CONNECT INJECTOR CONNECTORS
HINT: The No.1 and No.3 injector connectors are gray, and the No.2 and No.4 injector connectors are dark gray

5. CONNECT THROTTLE BODY AND AIR INTAKE CHAMBER COVER ASSEMBLY
- Place a new gasket on the intake manifold.
- Using a 6 mm hexagon wrench, connect the throttle body and chamber cover assembly with the 3 bolts and 2
Connect these hoses and connectors:(1) 2 PCV hoses to cylinder head cover(2) Vacuum sensing hose to fuel p
6. INSTALL AIR CLEANER HOSE AND CAP
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications
Fuel Pressure Regulator: Specifications

Regulator Bolts ....................................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 2390
Fuel Pressure Regulator: Service and Repair
FUEL PRESSURE REGULATOR REMOVAL
HINT: Put a suitable container or shop towel under the pressure regulator.
3. REMOVE FUEL PRESSURE REGULATOR
- Remove the 2 bolts, and pull out the pressure regulator.
1. DISCONNECT
- Remove theVACUUM
0-ring fromSENSING HOSE
the pressure FROM FUEL PRESSURE REGULATOR2. DISCONNECT FUEL
regulator.
FUEL PRESSURE REGULATOR INSTALLATION
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Specifications > Page 2391

1. INSTALL FUEL PRESSURE REGULATOR
- Apply a light coat of gasoline to a new 0-ring, and install it to the pressure regulator.
- While turning the pressure regulator left and right, install it to the delivery pipe.
- Install the pressure regulator with the 2 bolts.
2. CONNECT FUEL RETURN HOSE TO FUEL PRESSURE REGULATOR3. CONNECT VACUUM SENSING H
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications


> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 2396
HINT:
At Fusible link
- H-fuse (AM2 30A)
- EFI main relay
- Fuel pump
- Check that the
(-) terminal 12from

HINT:
-

-
Fuel hoses
is low, connections
- Fuel pump
- Fuel filter
- Start the engine.

(2.7 - 3.1 kgf/sq.cm, 38 - 44 psi)


- Stop the engine.
-

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Circuit Opening Relay <--> [Fuel Pump Relay] > Component Information > Testing and Inspection




> Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Circuit Opening Relay <--> [Fuel Pump Relay] > Component Information > Testing and

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Testing and Inspection
Fuel Return Line: Testing and Inspection
FUEL LINES AND CONNECTIONS INSPECTION

- Check the fuel lines for cracks or leakage, and all connections for deformation.
- Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage.
- Check the fuel tank for deformation, cracks fuel leakage or tank band looseness.
- Check the filler neck for damage or fuel leakage.
- Hose and tube connections are as shown in the illustration.
- If a problem is found, repair or replace the part as necessary.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Testing and Inspection
Fuel Supply Line: Testing and Inspection

> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service Precautions > General Fuel System Precautions
Fuel Tank: Service PrecautionsGeneral Fuel System Precautions
WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce
- Keep a dry chemical (Class B) fire extinguisher near the work area.
- Place a "CAUTION FLAMMABLE" sign in the work area.
- Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away.
- Wear eye protection.
-
Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatur
- Relieve the fuel system pressure prior to disconnecting fuel system components.
- Use a suitable container to store or catch fuel.
- Do not replace fuel pipe with fuel hose.
- Plug all disconnected fuel line fittings and hoses.
- After making any fuel system repairs ALWAYS inspect for fuel leaks.
- Keep gasoline away from rubber or leather parts.
- Do not smoke or work near an open flame when working on the fuel system.
- Before working on the fuel system, disconnect the negative (-) terminal cable from the battery.
HINT:
Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is rem
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service Precautions > General Fuel System Precautions > Page 2413
Fuel Tank: Service PrecautionsFuel System Safety Procedures
FUEL SYSTEM
Union Bolt Type:

Flare Nut Type:

--
HINT:
Use a torque wrench with a fulcrumlength of 30 cm (11.81 in.).

3. Observe the following precautions when removing and installing the injectors.
- Never reuse the 0-ring.
- When placing a new 0-ring on the injector, take care not to damage it in any way.
- Coat a new 0-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil.
4. Install the injector to the delivery pipe and intake manifold as shown in the illustration.
5. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system.
- If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to t

- Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4kgf/sq.cm, 57
- In this state, check to see that there are no leaks from any part of the fuel system.
NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack.

- Remove the TOYOTA hand-held tester.
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service Precautions > Page 2416
Fuel Tank: Service and Repair
COMPONENTS
PRECAUTIONS
1. Always use new gaskets when replacing the fuel tank or component parts.2. Apply the proper torque to all parts tig
> Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Component Information > Service Precautions > Page 2417

> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Component Inspection
Idle Speed/Throttle Actuator - Electronic: Testing and InspectionComponent Inspection
IAC VALVE INSPECTION

INSPECT IAC VALVE OPERATION
Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check
-- Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check
- If operation is not as specified, replace the IAC valve.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Component Inspection > Page
Idle Speed/Throttle Actuator - Electronic: Testing and InspectionOn-Vehicle Inspection

1. INSPECT IAC VALVE OPERATION
-
Engine
Initial at normal operating temperature
conditions:-
- Idle speed set correctly
- Transmission in neutral
-
Using SST, connect terminals TE1 and E1 of the DLC1.SST 09843-18020
-
After engine speed are kept at 900 - 1,300 rpm for 5 seconds, check that they return to idle speed. If the rpm o
- Remove the SST from the DLC1. SST 09843-18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE: "Cold" and "Hot" in those sentences express the temperature of the coils themselves."Cold" is
- Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO).
Resistance:Cold: 17.0 - 24.5 ohmHot: 21.5 - 28.5 ohm

- If resistance is not as specified, replace the IAC valve.
- Reconnect the IAC valve connector.
> Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator - Electronic > Component Information > Testing and Inspection > Page 2423
Idle Speed/Throttle Actuator - Electronic: Service and Repair
IAC VALVE REMOVAL
1. REMOVE THROTTLE BODY2. REMOVE IAC VALVE

- Remove the 4 screws, IAC valve and gasket.
INSTALLATION HINT: Place a new gasket on the throttle body.

> Powertrain Management > Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations

> Powertrain Management > Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page
2427

2428

2429

Details
2430

Body (Fig 19)
2431

Body (Fig 19)
Locations
> Powertrain Management > Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 2432



2433

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel Pump Relay] > Component Inform




> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Circuit Opening Relay <--> [Fuel Pump Relay] >
Component Information > Testing and Inspection > Page 2438

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Comp

> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > EFI Main Relay <--> [Main Relay (Computer/Fuel System)] > Comp
2447




> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > D

Ground Points
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Page 2458



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Page 2468
> Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > P

CIRCUIT DESCRIPTION
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications
Throttle Body: Specifications

Throttle Body Bolts ............................................................................................................................................................
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > On-Vehicle Inspection
Throttle Body: Testing and InspectionOn-Vehicle Inspection
1. INSPECT THROTTLE BODY
- Check that the throttle linkage moves smoothly.
-
Start
Check thethe engine.at each port.-
vacuum
- Check the vacuum with your finger.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > On-Vehicle Inspection > Page 2475
Throttle Body: Testing and InspectionComponent Inspection

THROTTLE BODY INSPECTION
1. CLEAN THROTTLE BODY

- Using a soft brush and carburetor cleaner, clean the cast parts.
- Using compressed air, clean all the passages and apertures.
NOTICE: To prevent deterioration, do not clean the TP sensor.
2. INSPECT THROTTLE VALVE

-
w/ Throttle opener:Apply vacuum to the throttle opener.
- Check that there is no clearance between the throttle stop screw and throttle lever when the closed throttle pos
3. INSPECT THROTTLE POSITION SENSOR
-
- Insert a feeler gauge between the throttle stop screw and stop lever.
- Using an ohmmeter, measure the resistance between each terminal.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > On-Vehicle Inspection > Page 2476

4. IF NECESSARY, ADJUST THROTTLE POSITION SENSOR
- Loosen the 2 set screws of the throttle position sensor.
-
- Insert a 0.70 mm (0.028 in.) feeler gauge between the throttle stop screw and stop lever.
- Connect the test probe of an ohmmeter to the terminals IDL and E2 of the throttle position sensor.
- Gradually turn the throttle position sensor clockwise until the ohmmeter deflects, and secure it with the 2 set s
- Recheck the continuity between terminals IDL and E2.
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Testing and Inspection > Page 2477
Throttle Body: Service and Repair
THROTTLE BODY REMOVAL
1. DRAIN ENGINE COOLANT2. REMOVE AIR CLEANER HOSE AND CAP

- Disconnect the IAT sensor connector.
- Loosen the air cleaner hose clamp bolt.
- Disconnect the 4 air cleaner cap clips.
- Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the air cle
3. DISCONNECT ACCELERATOR CABLE BRACKET FROM THROTTLE BODY4. REMOVE THROTTLE BO
- Disconnect the 2 EGR vacuum hoses.

- Disconnect the EVAP vacuum hose.
- Disconnect the throttle position sensor connector.
- Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the air intake chamber.
- Remove the throttle body gasket.
- Disconnect the 2 water bypass hoses and air hose, and remove the throttle body.
THROTTLE BODY INSTALLATION
1. INSTALL THROTTLE BODY

- Connect the air hose and water bypass hoses to the throttle body.
- Install a new gasket on the air intake chamber, facing the protrusion downward.
- Install the throttle body with the 2 bolts and 2 nuts in the sequence shown.

- Connect the IAC valve connector.
- Connect the throttle position sensor connector.
- Connect the EVAP vacuum hose.
-
w/ EGR:Connect the 2 EGR vacuum hoses.
2. CONNECT ACCELERATOR CABLE BRACKET TO THROTTLE BODY
3. INSTALL AIR CLEANER HOSE AND CAP4. FILL RADIATOR WITH ENGINE COOLANT
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions >
Page 2484

Power Source
Key to Diagrams
Page 2485

Power Window
Page 2486

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.
Page 2487

Wiring Color
Example:
Splice Point
Shielded Cable
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2488
Page 2489

Page 2490

Page 2491

Special Tool

Page 2492

HINT:
"Case 1"
"Case 2"

: Connector Body
Page 2493

"Case 1"
HINT:
"Case 2"
Page 2494

Terminal Retainer
Locking Lug

HINT:
Page 2495


Page 2496

CAUTION:
Voltage Check
ON
Page 2497

Voltage Check
ON
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2498
> Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Diagrams > Page 2499

CIRCUIT DESCRIPTION
> Powertrain Management > Ignition System > Firing Order > Component Information > Specifications
> Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations
> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions

Ground Points
> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2512

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
> Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2527

CIRCUIT DESCRIPTION
> Powertrain Management > Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Specifications > Electrical Specifications

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
> Powertrain Management > Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Specifications > Electrical Specifications > P

Torque ..................................................................................................................................................................................
> Powertrain Management > Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram Information and Instruc

Ground Points
> Powertrain Management > Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Diagram

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Diagrams > Page 2550

CIRCUIT DESCRIPTION





> Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications
Torque ..................................................................................................................................................................................
> Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Specifications > Page 2556

Ignition Coil




Distributor

7. INSPECT AIR GAP
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)


DISTRIBUTOR REMOVAL





6. REMOVE CONDENSER
INSPECT SHAFT

NOTICE:




> Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications

> Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 2566





> Powertrain Management > Ignition System > Ignition Cable > Component Information > Specifications > Page 2567


> Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications
Ignition Coil: Specifications

Primary coil resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
Secondary coil resistance:

Cold
.............................................................................................................................................................................
Hot
..............................................................................................................................................................................
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions
Ignition Coil: Diagram Information and Instructions

Ground Points
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Diagram Information and Instructions > Page 2573

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Ignition Coil: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
> Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Page 2588
Ignition Coil: Description and Operation

CIRCUIT DESCRIPTION
Ignition Coil: Testing and Inspection

Ignition Coil




Distributor

7. INSPECT AIR GAP
Air gap: 0.2 - 0.4 mm (0.008 - 0.016 in.)


> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instru

Ground Points
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2611

CIRCUIT DESCRIPTION
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Spe

Resistance:
Cold .............................................................................................................................................................................
Hot ..............................................................................................................................................................................
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Spe
> Page 2616

Torque ..................................................................................................................................................................................
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component Information > Dia
Instructions

Ground Points
> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Engine RPM Sensor (NE signal) <--> [Crankshaft Position Sensor] > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION





> Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair
> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications

Recommended plugs
NGK BKR5EYA
Plug gap 0.031 in

> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 2644

Torque .................................................................................................................................................................................
> Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 2645





> Powertrain Management > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Compone
Inspection
Shift Interlock Solenoid: Testing and Inspection
1. Disconnect solenoid connector.2. Using suitable ohmmeter, measure resistance between both terminals.3. Resistan
a. Corolla and MR2: 21-27 ohms.b. RAV4: 26-33 ohms.c. Celica: 30-37 ohms.
4. Apply battery positive voltage between terminals and ensure solenoid operating noise can be heard.
> Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Componen

> Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control
Module > Component Information > Testing and Inspection > Page 2657





> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Infor

> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T

Ground Points
> Powertrain Management > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position
Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 2669

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Specifications
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications
Band Apply Servo: Specifications

SECOND COAST BRAKE
Piston Stroke .....................................................................................................................................................................
..........................................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Specifications > Page 2702
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Specifications
Case: Specifications
Transaxle Rear Cover ..........................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications
Clutch: Specifications
DIRECT CLUTCH
Piston Stroke ......................................................................................................................................................... 1.37 -
....................................................................................................................................................................................
FORWARD CLUTCH
Piston Stroke ......................................................................................................................................................... 1.11 -
....................................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > Direct Clutch > Page 2711
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Sp
Differential Fluid - A/T: Capacity Specifications

AFTYPE ..............................................................................................................................................................................
CAPACITY, Refill
Camry, Avalon 4-cyl ............................................................................................................................................................
Corolla 3-speed ....................................................................................................................................................................
Celica 2.2L ...........................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Sp
Differential Fluid - A/T: Fluid Type Specifications
Differential Fluid Type (3 Speed A/T) ................................................................................................................. ATF D-I

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 2720
Differential Fluid - A/T: Testing and Inspection
To check differential fluid level:

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 2721
Differential Fluid - A/T: Service and Repair

ATF Replacement - 3 Speed A/T
1. Using a hexagon wrench, remove the drain plug and drain the fluid.2. Using a hexagon wrench, install the drain pl
ATF D-II or DEXRON III (DEXRON II)Fluid type:
5. Check differential fluid level. Remove the filler plug and check differential fluid level.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Fluid Interchangeability
Fluid - A/T: Technical Service BulletinsA/T - Fluid Interchangeability
Title:AUTOMATIC TRANSMISSION FLUIDS
Models:All Models
May 21, 1999
REVISION NOTICE:
The information contained in this TSB updates TC003-98 dated June 19, 1998.
Introduction
Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify
Please refer to the following table for the interchangeability between each ATF.
Affected Vehicles
^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV.
NOTICE:
With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed.
Parts Information
SIZE NEW PART NUMBER PART NAME
4 Liter 08886-01705 ATF Type T-IV

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Fluid Interchangeability > Page 2726
Fluid - A/T: Technical Service BulletinsA/T - Fluid Type T-IV Replaces Type T-II
June 19, 1998
Title:AUTOMATIC TRANSMISSION FLUID TYPE T-IV
Models:ALL MODELS
Introduction
The introduction of Automatic Transmission Fluid type T-IV makes type T-II obsolete. Use type T-IV for all applicatio
Affected Vehicles
^ All vehicles with Automatic Transmissions specified to use ATF Types T-II or T-IV.
Parts Information
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications

A/T Fluid (w/o Differential Oil)
Drain and Fill .......................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 2729
Fluid - A/T: Fluid Type Specifications
A/T Fluid
Type ....................................................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 2730
Fluid - A/T: Testing and Inspection

PRELIMINARY CHECK
1. CHECK FLUID LEVEL
HINT:
Drive the vehicle so that the engine and transaxle are at normal operating temperature.
-
ATF temperature: 70 - 80 C (158 - 176 F)
- Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does n
(a) Park the vehicle on a level surface and set the parking brake.(b) With the engine idling and the brake pedal de
position.
(c) Pull out the oil level gauge and wipe it clean.(d) Push it back fully into the pipe.(e) Pull it out and check that t
2. CHECK FLUID CONDITION

If the fluid smells burnt or is black, replace it.
3. REPLACE ATF
(a) Using a hexagon wrench, remove the drain plug and drain the ATF.(b) Using a hexagon wrench, install the dr

Drain end refill: 2.5 liters: (2.6 US qts, 2.2 Imp.qts)
(d) Start the engine and shift the selector into all positions from the P position through the L position and then shi
4. REPLACE DIFFERENTIAL FLUID IF NECESSARY
5. CHECK DIFFERENTIAL FLUID LEVEL

6. INSPECT AND ADJUST THROTTLE CABLE

(a) Fully depress the accelerator pedal and check that the throttle valve opens fully.
HINT; If the throttle valve does not open fully, adjust the accelerator link.
(a) Using a hexagon wrench, remove the drain plug and drain the fluid.(b) Using a hexagon wrench. install the dr

(b) Fully depress the accelerator.(c) Loosen the adjustment nuts.(d) Adjust the outer cable so that the distance bet
Standard boot and cable stopper distance:

0 - 1 mm (0-0.04 in.)
(e) Tighten the adjusting nuts.(f) Recheck the adjustments.
7. INSPECT PARK/NEUTRAL POSITION SWITCH

(a) Remove the park/neutral position switch.
(b) Using an ohmmeter, check continuity between each terminal shown below when the shift lever is put in each
8. ADJUST SHIFT CONTROL CABLE
(a) Remove the engine under cover.(b) Loosen the nut on the control shaft lever.(c) Push the control shaft lever fu

9. ADJUST PARK/NEUTRAL POSITION SWITCH
If the engine will start with the shift selector in any position other than the N or P position, adjustment is required
Torque: 5.4 Nm (55 kgf.cm, 48 in.Ibf)
Idle speed: 75050 rpm (In the N position and A/C OFF)
Fluid - A/T: Service and Repair

(ATF)1. Replace Automatic Transmission Fluid , as follows:
a. Using a hexagon wrench, remove the drain plug and drain the fluid.b. Using a hexagon wrench, install the drai
(P) (L) P
70 - the
d. Start 80Cengine
(158 -and
176F) Check
shift the fluidinto
the selector level
allwith the normal
positions fluid
from the temperature
Park and
through the add and
Low as necessary.
then shift into the
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications
Fluid Pan: Specifications
Oil pan X Transaxle case .....................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Torque Specifications
Fluid Pump: SpecificationsTorque Specifications

TORQUE SPECIFICATIONS
Stator Shaft X Oil Pump Body .........................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Torque Specifications > Page 2742
Fluid Pump: SpecificationsService Specifications

SERVICE SPECIFICATIONS
Body Clearance:
Standard .......................................................................................................................................................... 0.07 -
Tip Clearance:
Standard .......................................................................................................................................................... 0.11 -
Side Clearance:
Standard .......................................................................................................................................................... 0.02 -
Drive And Driven Gear Thickness:

Mark
A ............................................................................................................................................................ 9.440 - 9
Pump Body Busing Inside Diameter:
Maximum ...................................................................................................................................................................
Stator Shaft Busing Inside Diameter
Front Side Maximum ..................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 2743
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > Page 2744
Fluid Pump: Service and Repair
For information regarding the service and repair of this component and the system that it is a part of, please refer to Au
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Specifications
Governor: Specifications
Differential Gear Ratio 3.526..........................................................................................................................................
Vehicle Speed ...................................................................................................................................................................

Differential Gear Ratio 3.722...........................................................................................................................................
Vehicle Speed ...................................................................................................................................................................

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications
Intermediate Shaft: Specifications

INTERMEDIATE SHAFT
End Play ................................................................................................................................................................ 0.49 -
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 2751
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Intermediate Shaft, A/T > Component Information > Specifications > Page 2752
Intermediate Shaft: Service and Repair
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Specifications
Planetary Gears: Specifications

FRONT PLANETARY GEAR
Sun Gear Bushing Inside Diameter:
Standard .................................................................................................................................................. 22.025 - 22
Ring Gear Flange Bushing Inside Diameter:
Standard .................................................................................................................................................. 19.025 - 29
Planetary Pinion Gear Thrust Clearance:
Standard .............................................................................................................................................................. 0.20
REAR PLANETARY GEAR

Planetary Pinion Gear Thrust Clearance:
Standard ............................................................................................................................................................ 0.20

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams > Front Planetary Gear
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Diagrams > Front Planetary Gear > Page 2758
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Testing and Inspection

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Testing and





> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Testing and Inspection

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diag

Ground Points
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information >

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable
Page 2778



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
Page 2788
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Pag

CIRCUIT DESCRIPTION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Control Module > Component Information > Testing and Inspection

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Control Module > Component Information > Testing and





> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Testing and Inspection
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Testing and Inspection

> Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications
Speedometer Gear, A/T: Specifications

Speedometer Driven Gear:
Oil Seal Drive In Depth ....................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Speedometer Gear, A/T > Component Information > Specifications > Page 2806
Speedometer Gear, A/T: Service and Repair

REMOVAL
(SST)1. Remove speedometer driven gear oil seal. Using Special Service Tool 09921-00010 or equivalent, pull out
INSTALLATION
1. Install speedometer driven gear oil seal using SST 09201-10000 (09201-01080) or equivalents.
19 mm (0.75 inch)Drive in depth: .
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications
Throttle Valve Cable/Linkage: Specifications

THROTTLE CABLE ADJUSTMENT
Distance Between Boot End Face And Inner Cable Stopper:
Throttle Valve Fully Opened ......................................................................................................................................
TIGHTENING SPECIFICATIONS
Throttle Cable Retaining Bolt .............................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Specifications > Page 2810
Throttle Valve Cable/Linkage: Adjustments

THROTTLE CABLE ADJUSTMENT
Inspect and adjust throttle cable, as follows:a. Depress the accelerator pedal all the way and check that the throttle va
HINT: If the throttle valve does not open fully, adjust the accelerator link.
b. Fully depress the accelerator.

c. Loosen the adjustment nuts.
d. Adjust the outer cable so that the distance between the end of the boot and stopper on the cable is the standard.
Standard boot and cable stopper distance: O - 1 mm (O - 0.04 inch).
Recheck
e. Tighten thethe adjustments.
adjusting nuts.f.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Bolt Installation
Torque Converter: Technical Service BulletinsA/T - Torque Converter Bolt Installation Precautions
T-SB-0014-11
February 17, 2011
Torque Converter Bolt Installation
Service CategoryDrivetrain
SectionAutomatic Transmission/Transaxle
MarketUSA
Applicability
Introduction
NOTE
Not all applications will use washers on the torque converter bolts.
Installation Procedure
^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when
The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during
^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly.
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter
Bolt Installation Precautions > Page 2815

^ Torque the bolts to the specification found in the applicable Repair Manual.
NOTE
In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 2816
Torque Converter: Testing and Inspection

TORQUE CONVERTER
Torque Converter Cleaning
If the transaxle is contaminated, the torque converter and transaxle cooler should be thoroughly flushed with ATF
-
Torque Converter Inspection
1. INSPECT ONE-WAY CLUTCH
a. Install SST in the inner race of the one-way clutch. SST 09350-32014 (09351-32010)b. Install SST so that it fi
SST 09350-32014 (09351-32020)
c. With the torque converter clutch standing on its side, the clutch should lock when turned counterclockwise, and
smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter if the clutch
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 2817
Torque Converter: Service and Repair
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications
Torque Converter Clutch: Specifications

Torque Converter Clutch Runout:
Maximum .........................................................................................................................................................................
Torque Converter Clutch:
Installation Distance .........................................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Specifications > Page 2821
Torque Converter Clutch: Testing and Inspection

TORQUE CONVERTER CLUTCH INSPECTION
1. Inspect one-way clutch, as follows:
(SST)
a. Install Special Service Tool 09350-32014 (09351-32010) or equivalents, in the inner race of the one-way clutc
clutch.
c. With the torque converter clutch held upright, the clutch should lock when turned counterclockwise, and shoul
clockwise. If necessary, clean the converter and retest the clutch. Replace the converter clutch if the clutch sti
2. Measure torque converter clutch sleeve runout. Temporarily mount the torque converter clutch to the drive plate. S
0.30 mm (0.0118 inch) the torque converter clutch sleeve runout.Maximum runout: If the runout is not within the
NOTE: Mark the position of the converter clutch to ensure correct installation.
TORQUE CONVERTER CLUTCH INSTALLATION CHECK

23.0 mm (0.906 inch)Using calipers and a straight edge, measure the distance from the installed surface to the fr
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructi

Ground Points
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Diagram

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Diagrams > Page 2841

CIRCUIT DESCRIPTION
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Valve Body Spring Specifications
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Valve Body Spring Specifications > Page 2846
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > Valve Body Spring Specifications > Page 2847
Valve Body: SpecificationsTorque Specifications
Lower Valve Body Cover X Lower Valve Body .................................................................................................................
8 mm Bolt .........................................................................................................................................................................
Valve Body X Transaxle Case .............................................................................................................................................
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Upper Valve Body
Valve Body: LocationsUpper Valve Body
A131L Aisin AW Product

A131L Toyota Product And A132L
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Upper Valve Body > Page 2850

Valve Body: LocationsLower Valve Body

A131L Toyota Product

A132L
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Valve Body Assembly
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Valve Body Assembly > Page 2855
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Valve Body Assembly > Page 2856
> Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Page 2857
Valve Body: Service and Repair
> Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications
Clutch Disc: Specifications

Disc Rivet Head Depth:
Minimum ..........................................................................................................................................................................
Disc Runout:
Maximum .........................................................................................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 2862
Clutch Disc: Testing and Inspection
1. Inspect clutch disc for wear or damage. Using calipers, measure the rivet head depth.
0.3 mm (0.012 inch)
Minimum rivet depth: . If necessary, replace the clutch disc.
2. Inspect clutch disc runout. Using a dial indicator, check the disc runout.
0.8 mm (0.031 inch)
Maximum runout: . If necessary, replace the clutch disc.
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications

SAE J1703 or FMVSS No. 116 DOT 3Specified type ......................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications
Clutch Master Cylinder: Specifications

Slotted Spring Pin Protrusion ...........................................................................................................................................
Master Cylinder:
Installation Nut ...........................................................................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Specifications > Page 2870
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Replacement
Clutch Master Cylinder: Service and RepairReplacement
REMOVAL
1. Remove brake booster.2. Draw out fluid with syringe.
3. Disconnect clutch line.

(SST)
15 Nm (11 ft. lbs.)Using Special Service Tool 09023-00100 or equivalent, disconnect the clutch line. Use a cont
12 Nm (108 inch lbs.)Torque: .
INSTALLATION
INSTALLATION NOTE: After installation, bleed system and adjust clutch pedal.
4. Remove lower finish panel.5. Remove duct heater to resister No.2.6. Remove clip and pin.7. Remove two mountin
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Replacement > Page 2873
Clutch Master Cylinder: Service and RepairOverhaul

DISASSEMBLY
1. Remove reservoir tank, as follows:
a. Using a pin punch and hammer, drive out the slotted spring pin.b. Remove the reservoir tank and grommet.
2. Remove push rod, as follows:
a. Pull back the boot and, using snap ring pliers, remove the snap ring.b. Pull out the push rod and washer.c. Rem
ASSEMBLY
1. Coat parts with lithium soap base glycol grease, as shown.2. Insert piston into cylinder.3. Install push rod assembl
a. Install the reservoir tank and a new grommet.b. Using a pin punch and hammer, drive in the slotted spring pin.
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications
Clutch Slave Cylinder: Specifications

Release Cylinder:
Installation Bolt ................................................................................................................................................................
Bleeder Plug .........................................................................................................................................................................

> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 2877
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Replacement
Clutch Slave Cylinder: Service and RepairReplacement
REMOVAL
1. Disconnect clutch line.

(SST)
15 Nm (11 ft. lbs.)Using Special Service Tool 09023-00100 or equivalent, disconnect the clutch line. Use a cont
2. Remove two bolts and pull out release cylinder.
12 Nm (108 inch lbs.)Torque: .
INSTALLATION
INSTALLATION NOTE: After installation, bleed the clutch system.

> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Replacement > Page 2880
Clutch Slave Cylinder: Service and RepairOverhaul

DISASSEMBLY
1. Remove bleeder plug.
8.3 Nm (74 inch lbs.)Torque: .
2. Pull out boot with push rod.
3. Remove piston. Using compressed air, remove the piston with the spring from the cylinder.
ASSEMBLY
1. Coat piston with lithium soap base glycol grease, as shown.2. Install piston with spring into cylinder.3. Install boo
> Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Specifications
Hydraulic Hose: Specifications
Clutch Line Union ................................................................................................................................................................

> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications
Clutch Pedal Assembly: Specifications

Pedal Height:
From Asphalt Sheet .................................................................................................................................................... 138
Pedal Freeplay ......................................................................................................................................................................

From Pedal Full Stroke End Position ...............................................................................................................................
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 2887
Clutch Pedal Assembly: Adjustments

CLUTCH PEDAL ADJUSTMENT
1. Check pedal height.
138.4-148.4 mm (5.449-5.843 inch)Pedal height from asphalt sheet: .
2. If necessary, adjust pedal height. Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten t
Pedal freeplay: 1.0-5.0 mm (0.039-0.197 inch)
Push rod play at pedal top: 5.0-15.0 mm (0.197-0.591 inch). Gently push on the pedal until the resistance begi
4. If necessary, adjust pedal freeplay and push rod play, as follows:
a. Remove the duct heater to resister and the lows finish panel.
b. Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct.c. Tighten the lock n
5. Check clutch release point, as follows:
a. Pull the parking brake lever and install wheel stopper.b. Start the engine and idle the engine.c. Without depress
d. Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release
25 mm (0.98 inch)position.Standard distance: or more (From pedal stroke end position to release point).
> Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 2888

Inspect
If the pedal
distance notheight.
as specified, perform the following operation.-
- Inspect push rod play and pedal freeplay.
- Bleed the clutch line.
- Inspect the clutch cover and disc.
6. Check clutch start system, as follows:
a. Check that the engine does not start when the clutch pedal is released.b. Check that the engine starts when the c
7. Inspect clutch start switch continuity. Check the continuity between terminals when the switch is ON and OFF.
Switch Position: On Pushed.Condition: ContinuitySwitch Position: Off (Free)Condition: No Continuity

> Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Testing and Inspection
Clutch Release Bearing: Testing and Inspection
1. Inspect release bearing. Turn the bearing by hand while applying force in the axial direction.
NOTE: The bearing is permanently lubricated and requires no cleaning or lubrication. If necessary, replace the r
> Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Specifications
Clutch Release Fork: Specifications
Release Fork Support ...........................................................................................................................................................

> Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications
Pressure Plate: Specifications

Diaphragm Spring Finger Wear:
Maximum Depth .........................................................................................................................................................

Diaphragm Spring Tip Non-Alignment:
Maximum ...................................................................................................................................................................
Clutch Cover to Flywheel ................................................................................................................................................

> Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 2898
Pressure Plate: Testing and Inspection
1. Inspect diaphragm spring for wear.
Using calipers, measure the diaphragm spring for depth and width of wear. Maximum:
0.5 mm (0.020 inch)
6.0 mm (0.236 inch)
A (Depth): .B (Width): . If necessary, replace the clutch cover.
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Fluid (3 speed type automatic transmission only)
Capacity ...............................................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2904
Fluid - Differential: Fluid Type Specifications
Differential Fluid (3 speed automatic transmission only)
Type .....................................................................................................................................................................................
> Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Technical Service Bulletins > M/T - Ring Gear Set Bolt Torque Specification D
Ring Gear: Technical Service BulletinsM/T - Ring Gear Set Bolt Torque Specification Decreased
REF.: TRANSMISSION & CLUTCH
NO.: TC95-010
MODEL: COR & CEL
C40, C5 # TRANSAXLE RING GEAR SET BOLT
Due to a transaxle production change on the Corolla and Celica models, differential lock plates have been discontinued
Transaxle Serial Number: From: Z50100001From: X50100021

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal/Installation
Axle Shaft: Service and RepairRemoval/Installation

FRONT DRIVE SHAFT COMPONENTS
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal/
Installation > Page 2915

FRONT DRIVE SHAFT REMOVAL
CAUTION:-
The hub bearing could be damaged if it is subjected to the vehicle weight. such as when moving the veh
SST 09608-16042 (09608-02021, 09608-02041)
- w/ABS:
CAUTION: After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the
1. REMOVE FRONT WHEEL
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
2. REMOVE ENGINE UNDER COVERS
3. DRAIN OUT GEAR OIL (M/T) OR ATF (A/T)
4. w/ABS:
REMOVE ABS SPEED SENSORRemove the bolt and ABS speed sensor.
5. REMOVE DRIVE SHAFT LOCK NUT

(a) Remove the cotter pin and lock nut cap.(b) While applying the brakes, remove the nut.
Torque: 216 N.m (2,200 kgf.cm. 159 ft.lbf) See TSB DL001-98, 3-6-98.

6. DISCONNECT TIE ROD END FROM STEERING KNUCKLE
(a) Remove the cotter pin and nut.
(b) Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011
7. DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM

Remove the bolt and 2 nuts.
Torque: 142 N.m (1,450 kgf.cm, 105 ft.lbf)
8. DISCONNECT DRIVE SHAFT FROM AXLE HUB

Using a plastic hammer, disconnect the drive shaft from the axle hub.
CAUTION: Be careful not to damage the boot, oil seal and speed sensor rotor.
9. REMOVE DRIVE SHAFT

LH Drive shaft
:Using a hammer and hub nut wrench, remove the drive shaft from the transaxle.

RH Drive shaft
:Using a hub nut wrench, remove the drive shaft from the transaxle.
CAUTION: Be careful not to damage the dust cover and oil seal.
Coat the seal lip HINT:

INSTALLATION with MP- grease.
- Before installing the drive shaft, set the snap ring opening side facing downward.
- Whether or not the drive shaft is making contact with the pinion shaft can be known by the sound or feeling w
- 2-3 mm (0.08-0.12 in.)After installation, check that there is of play in axial direction.
- After installation, check that the drive shaft cannot be pulled out by hand.
10. REMOVE SNAP RING

Using a screwdriver, remove the snap ring from the inboard joint spline.
FRONT DRIVE SHAFT INSTALLATION

HINT: After installation, check ABS speed sensor signal and front wheel alignment.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal/Installation > Page 2918
Axle Shaft: Service and RepairDisassembly/Assembly
FRONT DRIVE SHAFT DISASSEMBLY

1. CHECK DRIVE SHAFT
(a) Check to see that there is no obvious play in the outboard joint.(b) Check to see that the inboard joint slides sm
2. REMOVE INBOARD JOINT BOOT CLAMPS
TOYOTA type
:(a) Using a screwdriver, remove the 2 boot clamps.(b) Slide the inboard joint boot toward the outboard joint.
SAGINAW type
:(a) Using pliers, draw clamp hooks together and remove the large clamp.(b) Using a side cutter, cut the small bo
3. REMOVE INBOARD JOINT TULIP
(a) Place matchmarks on the inboard joint tulip, tripod and drive shaft.(b) Remove the inboard joint tulip from the
4. REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.(b) Place matchmarks on the drive shaft and tripod.(c) Usin

NOTICE: Do not tap the roller.
5. REMOVE INBOARD JOINT BOOT
6. RH DRIVE SHAFT:
REMOVE DYNAMIC DAMPER(a) Using a screwdriver, remove the clamp of the dynamic damper.(b) Remove
7. REMOVE OUTBOARD JOINT BOOT
(a) Using a screwdriver, remove the 2 boot clamps of the outboard joint boot.(b) Remove the boot from the outbo
NOTICE: Do not disa8sembIe the outboard joint.
6. REMOVE DUST COVER
SST 09950-00020Using SST and a press, remove the dust cover from the inboard joint tulip.
9. REMOVE NO.2 DUST DEFLECTOR
(a) Mount the outboard joint shaft in a soft jaw vise.(b) Using a screwdriver and hammer, remove the No.2 dust d
CAUTION: Be careful not to damage the ABS speed sensor rotor.

FRONT DRIVE SHAFT ASSEMBLY
1. INSTALL NEW NO.2 DUST DEFLECTOR Using SST and a press, install a new No.2 dust deflector.

SST 09309-36010,09316-20011
CAUTION: Be careful not to damage the ABS speed sensor rotor.
2. INSTALL NEW DUST COVER

Using a press, install the inboard joint tulip into a new dust cover.
3. TEMPORARILY INSTALL BOOTS, DAMPER (RH DRIVE SHAFT) AND NEW CLAMPS
HINT
Before installation the boot, wrap vinyl tape around the spline of the drive shaft to prevent the boot from dam
^:^ RH Drive shaft: Fix the clamp position in line with the groove of the drive shaft.
4. INSTALL TRIPOD
(a) TOYOTA Type:
Place the beveled side of the tripod axial spline toward the outboard joint.
(b) Align the matchmarks placed before removal.(c) Using a brass bar and hammer, tap in the tripod to the drive
NOTICE: Do not tap the roller.
(d) Using a snap ring expander, install a new snap ring.
5. INSTALL BOOT TO OUTBOARD JOINT

Before assembling the boot, fill grease into the outboard joint and boot.
HINT: Use the grease supplied in the boot kit.
6. INSTALL INBOARD JOINT TULIP TO FRONT DRIVE SHAFT
(a) Pack the inboard joint tulip and boot with grease. HINT: Use the grease supplied in the boot kit.(b) Align the
Install the inboard joint tulip to the drive shaft.(d) Temporarily install the boot to the inboard joint tulip.
7. ASSEMBLE BOOT CLAMPS AND DYNAMIC DAMPER CLAMP (RH DRIVE SHAFT)
(a) Check that the boots are on the shaft groove.(b) Make sure that the boots are not stretched or contracted when
Drive shaft standard length
(c) Bend the clamp and lock it.

8. RH DRIVE SHAFT:
ASSEMBLY DAMPER CLAMP(a) Be sure the damper is on the shaft groove.

(b) Set the distance. as shown in image.
Distance:
TOYOTA: 431.6 mm 5.0 mm (16.992 0.197 in.)SAGINAW: 431.5 mm 3.0 mm (16.988 0.118 in.)
(c) Place a new damper clamp to the damper.(d) Bend the band and lock it with a screwdriver.
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Technical Service Bulletins > Drivetrain - R
Constant Velocity Joint: Technical Service BulletinsDrivetrain - Revised Drive Shaft Grease
April 09, 1999
Title:REVISED DRIVE SHAFT GREASE
Models:RAV4, Tercel, Corolla, Celica, Camry, Supra
Introduction: The greases supplied in replacement Inboard and Outboard Drive Shaft Boot Kits for the following mode
With this revision, the grease compositions have been changed and are now both the same color. To correctly lubricate
NOTE:
Although inboard and Outboard greases are now the same color, their compositions ere different.
Affected Vehicles:All RAV4, Tercel1 Corolla, Celica, Camry and Supra Models.
Required Tools and Material:As outlined in the Service Repair Manual.
Repair Procedure:Refer to the appropriate Repair Manual for installation and lubrication information for Drive Shaft Jo
Warranty Information:
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > Drivetra
Constant Velocity Joint Boot: Technical Service BulletinsDrivetrain - Revised Drive Shaft Grease
April 09, 1999
Title:REVISED DRIVE SHAFT GREASE
Models:RAV4, Tercel, Corolla, Celica, Camry, Supra
Introduction: The greases supplied in replacement Inboard and Outboard Drive Shaft Boot Kits for the following mode
With this revision, the grease compositions have been changed and are now both the same color. To correctly lubricate
NOTE:
Although inboard and Outboard greases are now the same color, their compositions ere different.
Affected Vehicles:All RAV4, Tercel1 Corolla, Celica, Camry and Supra Models.
Required Tools and Material:As outlined in the Service Repair Manual.
Repair Procedure:Refer to the appropriate Repair Manual for installation and lubrication information for Drive Shaft Jo
Warranty Information:
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Front
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Front > Page 2935
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 2936



5. w/ABS:



1. Remove lock nut.
2. Remove axle hub.

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drive Axles - Front Hub Nut Replacem
MARCH 6, 1998
Introduction
NOTE:
Affected Vehicles
Parts Information

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 2947
> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: >
Squeaking Noise From Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > SU00696 > N
Noise From Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Drivetrain - Drive/Axle Shaft
Drive/Propeller Shaft: Technical Service BulletinsDrivetrain - Drive/Axle Shaft Replacement Precautions
Title:DRIVESHAFT ASSEMBLYREPLACEMENT
Models:'90 - '07 Toyota
IntroductionThe purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on rep
Applicable Vehicles
^ 1990 - 2007 model year Toyota vehicles.
Repair Procedure
Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease
NOTE:
A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more in
> Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > A/T - Torque Converter Bolt Installation Precautions
Flex Plate: Technical Service BulletinsA/T - Torque Converter Bolt Installation Precautions
T-SB-0014-11
February 17, 2011
Torque Converter Bolt Installation
Service CategoryDrivetrain
SectionAutomatic Transmission/Transaxle
MarketUSA
Applicability
Introduction
NOTE
Not all applications will use washers on the torque converter bolts.
^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when
The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during
^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly.
> Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > A/T - Torque Converter Bolt Installation Precautions > Page 2970

^ Torque the bolts to the specification found in the applicable Repair Manual.
NOTE
In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the
> Transmission and Drivetrain > Flex Plate > Component Information > Technical Service Bulletins > Page 2971
Flex Plate: Specifications
Drive Plate to Crankshaft Bolts 47 ft.lb

Tighten the bolts in 2 or 3 passes in sequence shown.
Drive Plate to torque Converter 20 ft.lb
Drive Plate runout (maximum) 0.0079 in
A/T Drive Plate Tightening Sequence

> Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel to Crankshaft Bolts58 ft.lb
Flywheel runout (maximum) 0.004 in Over limit, replace.
Flywheel Tightening Sequence

> Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Ring Gear, M/T > Component Information > Technical Service Bulletins > M/T - Ring G
Decreased
Ring Gear: Technical Service BulletinsM/T - Ring Gear Set Bolt Torque Specification Decreased
REF.: TRANSMISSION & CLUTCH
NO.: TC95-010
MODEL: COR & CEL
C40, C5 # TRANSAXLE RING GEAR SET BOLT
Due to a transaxle production change on the Corolla and Celica models, differential lock plates have been discontinued
Transaxle Serial Number: From: Z50100001From: X50100021

> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
M/T Fluid .............................................................................................................................................................................

> Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 2985
Fluid - M/T: Fluid Type Specifications
M/T Fluid
Grade ....................................................................................................................................................................................
Viscosity ..............................................................................................................................................................................
> Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Diagrams
Components
> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information > Testing and I

> Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Component Information
> Testing and Inspection > Page 2994





> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Testing and Inspect

> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information >
Instructions

Ground Points
> Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Comp
Inspection
> Transmission and Drivetrain > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control Module > Compo
Inspection

> Transmission and Drivetrain > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Shift Interlock Control





> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component I

> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor,

Ground Points
> Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position

Power Source
Key to Diagrams

Power Window

Connector
D: Connector Color
are pin numbers.
Example:
Junction Block

B
The= first
BlackBR
letter =indicates
Brown G the=basic
Green GRcolor
wire = Gray
and Lthe=second
BlueLGletter
= Light Greenthe
indicates 0 color
= Orange P stripe.

Wiring Color
Example:
Splice Point
Shielded Cable



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



CAUTION:
Voltage Check
ON

Voltage Check
ON

CIRCUIT DESCRIPTION
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection
ABS Light: Testing and Inspection

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 thi
WIRING DIAGRAM
Troubleshoot in accordance with the chart below for each trouble symptom.
Step 1
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Page 3066

Step 2
Step 3
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Testing and Inspection > Page 3067

Step 4
Step 5
> Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Testing and Inspection
> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System


> Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System > Page 3075

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > BR004-00 > Oc
Brake Pad: All Technical Service BulletinsBrakes - Pad Clicking Noise
BRAKESBR004-00
October 20, 2000
Title:BRAKE PAD CLICKING NOISE
Models:'90- '00 All Models
Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction
To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maint
1990 - 2000
Applicable model year Toyota vehicles, all models.
Vehicles^
Parts Information
Application ProcedureThere are two types of brake calipers: floating and fixed. Check the type of brake caliper installe
1. Floating Type Brake Caliper

A. Lift up or remove the brake caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the brake caliper.
B. If equipped with anti-squeal spring: Remove the anti-squeal springs.
C. Remove the brake pads with anti-squeal shims.
D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque pla
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: >
BR004-00 > Oct > 00 > Brakes - Pad Clicking Noise > Page 3085

E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plate
NOTE:
Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.
F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to th
G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illus
H. Install the brake pads with the anti-squeal shims.

I. If equipped with anti-squeal spring: Install the anti-squeal springs.
J. Press the piston in firmly and install the brake caliper.
NOTE
Clean excess grease. from brake pad and caliper.
^:^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.
K. Install the wheel assembly.
2.
Fixed Type Brake CaliperThere are two types of brake pads:

^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.)
^ Type "B": Has a flat upper and lower edge on the brake pad backing plate.
Type "A" Brake Pad
A. Remove the anti-squeal spring, clip and pad guide pin.
B. Remove the brake pads with the anti-squeal shims.
C. Clean any dust from the brake pads.

D. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the areas indicated in the illustratio
NOTE:
E. Install the brake pads with the anti-squeal shims.
NOTE:
Clean excess grease from the brake pads and caliper.
F. Install the pad guide pin, clip and anti-squeal spring.
G. Install the wheel assembly.

Type "B" Brake Pad
A. Remove the clip, pins and anti-rattle spring/pad retainer clip.
NOTE:
NOTE:

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > BR004-00 > Oct > 00 > Brak
Brake Pad: Customer InterestBrakes - Pad Clicking Noise
BRAKESBR004-00
October 20, 2000
Title:BRAKE PAD CLICKING NOISE
Models:'90- '00 All Models
Introduction A clicking type noise may be noticed when first applying the brakes after changing vehicle travel direction
To minimize this clicking noise, a disc brake caliper grease has been made available for use during brake service/maint
1990 - 2000
Applicable model year Toyota vehicles, all models.
Vehicles^
Parts Information
Application ProcedureThere are two types of brake calipers: floating and fixed. Check the type of brake caliper installe
1. Floating Type Brake Caliper

A. Lift up or remove the brake caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the brake caliper.
B. If equipped with anti-squeal spring: Remove the anti-squeal springs.
C. Remove the brake pads with anti-squeal shims.
D. Remove the pad support plates from the torque plate. Clean any dust from the pad support plates, torque pla
> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > BR004-00 >
Oct > 00 > Brakes - Pad Clicking Noise > Page 3093

E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the pad support plate
NOTE:
F. If the pad support plate is fixed to the torque plate with adhesive tape, perform the operation according to th
G. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to the caliper as indicated in the illus
H. Install the brake pads with the anti-squeal shims.

I. If equipped with anti-squeal spring: Install the anti-squeal springs.
J. Press the piston in firmly and install the brake caliper.
NOTE
Clean excess grease. from brake pad and caliper.
^:^ Do NOT apply grease to the friction surfaces of the brake pads or the disc rotor.
K. Install the wheel assembly.
2.
Fixed Type Brake CaliperThere are two types of brake pads:

^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.)
^ Type "B": Has a flat upper and lower edge on the brake pad backing plate.
Type "A" Brake Pad
A. Remove the anti-squeal spring, clip and pad guide pin.

NOTE:
NOTE:

Type "B" Brake Pad
A. Remove the clip, pins and anti-rattle spring/pad retainer clip.
NOTE:
NOTE:

> Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 3096
Brake Pad: Specifications
Front Brake Pad Thickness Standard Thickness 0.472 in
Minimum Thickness 0.039 in

Brake Pad: Service and Repair
Front Brake Components
REPLACEMENT
1. Remove front wheel.
Remove the wheel and temporarily fasten the Disc with Hub nuts.
Inspecting Pad Thickness Through Caliper Inspection Hole
2. Inspect pad lining thickness.
Minimum thickness: 1.0 mm (0.039 inch)Check the pad thickness through the Caliper inspection hole and repla
3. Remove Caliper from torque plate.
Removing 2 Installation Bolts

(a) Hold the sliding pin and loosen the 2 installation bolts.(b) Remove the 2 installation bolts.(c) Remove the Cal
NOTE: Do not disconnect the flexible hose from the Brake Caliper.
4. Remove these parts:
(a) 2 anti-squeal springs. (b) 2 Brake Pads.(c) 4 anti-squeal shims.(d) 4 pad support plates.
CAUTION:
The anti-squeal springs and support plates can be used again provided that they have sufficient rebound, no defor
5. Check Disc thickness and runout. 6. Install the 4 pad support plates.7. Install new pads.
CAUTION: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.
(a) Install 2 anti-squeal shims on each pad.
NOTE: Apply Disc brake grease to both sides of the inner anti-squeal shim.
(b) Install the 2 pads.
CAUTION: There should be no oil or grease adhering to the friction surfaces of the pads or the Disc.
(c) Install the 2 anti-squeal springs to the pad.

8. Install Caliper.
(a) Draw out a small amount of brake fluid from the reservoir.
Installing Piston And Caliper
(b) Press in the piston with a hammer handle or similar implement.
NOTE: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some
(c) Install the Caliper.(d) Install and torque the 2 installation bolts.
Torque:
9. Install 34 Nm (25 ft. lbs.)
front wheel.
10. Check that fluid level is at max line.
> Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications
Brake Rotor/Disc: Specifications
Front Brake Rotors Standard Thickness 0.866 in
Minimum Thickness 0.787 in
Maximum Runout 0.0020 in

> Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications
Brake Drum: Specifications
Standard Inside Diameter 7.874 in
Maximum Inside Diameter7.913 in

> Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Specifications
Brake Shoe: Specifications
Standard Lining Thickness 0.157 in
Minimum Lining Thickness 0.039 in

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System


> Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Bleeding the Brake System > Page 3114

> Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Required Brake Fluid SAE DOT3

> Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Testing and Inspection
> Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair
> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations

> Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 3131



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - Battery Maintenance and Testing
Battery: Technical Service BulletinsElectrical - Battery Maintenance and Testing
PRODUCT GENERAL INFORMATIONPG001-06
Title:BATTERY MAINTENANCE FORIN-STOCK VEHICLES & PRE-DELIVERY
Models:All Models & Model Years
January 26, 2006
November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recomm
Previous versions of this TSB should be discarded.
TSB UPDATE NOTICE:
The information contained in this TSB supersedes TSB No. PG017-02.TSB No. PGO17-02 is now obsolete and sho
Introduction
A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include
As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to l
To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dea
Applicable Vehicles
^ All models and model years.
> Starting and Charging > Battery > Component Information > Technical Service Bulletins > Electrical - Battery Maintenance and Testing > Page 3140

Required SSTs
Battery Inspection Procedure
All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/
In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used ONLY on the AUX
1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.)
2. Select the correct USER ID (if applicable) and press the NEXT soft key.
3. Enter USER PIN (if applicable) and press the NEXT soft key.
NOTE:
For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual.

4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu.
5. Choose BATTERY TEST and press the SELECT soft key.
6. Select IN VEHICLE and press the NEXT soft key.

7. Select MODEL and press the NEXT soft key.
NOTE:
^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery
^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing procedures.

8. Select the appropriate model and press the NEXT soft key.
9. Select OEM battery type and press the NEXT soft key.
10. Choose the correct battery (model number and CCA) and press the NEXT soft key.
11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and press the NEXT soft k

The battery is now being tested. The progress bar fills in across the screen while testing.
12. Read or print the battery test results (press the PRINT soft key to print).
Battery Inspection Results
Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results
1.
Battery Condition: "GOOD BATTERY" Return the battery to service.
2. Battery Condition: "GOOD-RECHARGE"
Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return it to service.
3. Battery Condition: "CHARGE & RETEST"
Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest.
NOTE:
Failure to fully charge the battery before retesting may cause false readings.
4.
Battery Condition: "REPLACE BATTERY"Replace the battery.
NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery.
5. Battery Condition: "BAD CELL-REPLACE"
Replace the battery. The decision indicates a bad cell within the battery.
CAUTION:
^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of 40F (4
^
NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND CAUS

Battery Charging Procedure
If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002-MC
1. Connect the charger cables to the positive (+) and negative (-) battery terminals.
2. Plug the charger into the 110V outlet and turn the switch to the ON position.
3. Select appropriate USER ID (if applicable) and press the NEXT soft key.
4. Enter USER PIN (if applicable) and press the NEXT soft key.
NOTE:
For details on defining USER ID or PIN, refer to the GR8 Instruction Manual.
5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu.

6. Select CHARGING from the Main Menu screen and press the SELECT soft key.
7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key.
8. Select IN VEHICLE and press the NEXT soft key.

9. Select MODEL and press the NEXT soft key.
NOTE:
^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the batte
^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing procedures.

10. Select the appropriate model and press the NEXT soft key.
11. Select OEM battery type and press the NEXT soft key.
12. Choose the correct battery (model number and CCA) and press the NEXT soft key.
The battery will be tested before charging will occur. The progress bar fills in across the screen while testing.

The charger starts charging upon completion of testing. The screen displays the status of charge.
13. Read or print the battery test results.
P 1/4: BATTERY RESULTS
P 2/4: STATE OF CHARGE (SOC)
P 3/4: STATE OF HEALTH (SOH)
P 4/4: WARRANTY CODE
To print:Align the Midtronics IR Printer(P/N 00002-A0870, component ofP/N 00002-V8150-KIT) in front of the
Battery Charging Results
Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results.
1. Battery Condition: "GOOD BATTERY"
Return the battery to service.

2. Battery Condition: "REPLACE BATTERY"
Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key.
NOTE:
A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery.
3. Battery Condition: "BAD CELL-REPLACE"
Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRA

Battery Replacement
If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to
Battery Maintenance
Recommended Battery Maintenance:
In addition to this new pre-delivery battery test, a monthly battery inspection is still required for stored vehicles. If you
To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-) battery cable should alwa
Refer to the appropriate model and year service bulletins for specific details. For example:
^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year)
^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year)
> Starting and Charging > Charging System > Alternator > Component Information > Service and Repair
Alternator: Service and Repair
Generator
REMOVAL GENERATOR
1. Remove Drive Belt
Loosen the pivot bolt and adjusting bolt, and remove the drive belt.Torque:
61 N.m (600 kgf.cm, 45 ft.lbf) 19 N.m (185 kgf.cm, 14 ft.lbf)Pivot bolt: Lock bolt:
2. Remove Generator
a. Disconnect the generator connector.b. Remove the nut, and disconnect the generator wire.c. Disconnect the wi
> Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Page 3153

INSTALLATION HINT: Install the slider, with that of groove facing toward as shown.
Installation is in the reserve order of removal.
Drive belt tension:
175 5 lbf
HINT:

> Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair
> Starting and Charging > Starting System > Starter Relay > Component Information > Locations

> Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 3161



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
> Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Page 3170



Details

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 3177



Details

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 3184



Details

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 3191



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information >



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page
3208

3209

3210

Details
3211

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations

> Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3215



Details

Body (Fig 19)
Locations
> Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - SRS And HV Wiring Repairs
Wiring Harness: Technical Service BulletinsElectrical - SRS And HV Wiring Repairs

SECTION: ELECTRICAL
BULLETIN # 156
DATE: AUGUST 2007
> Power and Ground Distribution > Fuse > Component Information > Locations
Fuse: Locations
> Power and Ground Distribution > Fuse > Component Information > Locations > Page 3227



Details

Body (Fig 19)
Locations
> Power and Ground Distribution > Fuse Block > Component Information > Locations

> Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 3234



Details

Body (Fig 19)
Locations
> Power and Ground Distribution > Fusible Link > Component Information > Locations

> Power and Ground Distribution > Fusible Link > Component Information > Locations > Page 3241



Details

Body (Fig 19)
Locations
> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations

> Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 3248



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations

> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 3257



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations

> Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3265



Details

Body (Fig 19)
Locations
> Power and Ground Distribution > Relay Box > Component Information > Locations

> Power and Ground Distribution > Relay Box > Component Information > Locations > Page 3272



Details

Body (Fig 19)
Locations
> Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Electrical - SRS And HV Wiring Repairs
Wiring Harness: Technical Service BulletinsElectrical - SRS And HV Wiring Repairs

SECTION: ELECTRICAL
BULLETIN # 156
DATE: AUGUST 2007
> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Alignment - Camber Adjusting Bolts
Alignment: Technical Service BulletinsAlignment - Camber Adjusting Bolts

REF.: SUSPENSION
NO.: SU0O4-96
DATE: JULY 12, 1996
MODEL: TER, PAS, COR, CAM,
AVL, CEL, PRV
CAMBER ADJUSTING BOLTS
To increase camber adjusting capability, the steering knuckle set bolts can be replaced with new camber adjusting bolts
NOTE:
Vehicles which are out of alignment specifications due to a collision or worn out parts, should be inspected for dam
To change camber, install the adjusting bolt in the lower steering knuckle mounting hole. If a camber change greater th
> Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Alignment - Camber Adjusting Bolts > Page 3285

CAMBER ADJUSTING BOLTS TABLE

STEERING KNUCKLE BOLT TORQUE SPECIFICATIONS:
Camber adjusting bolt values, bolt identification and part number information for current production models can also b
WARRANTY INFORMATION:*
*
Warrantable only for 12 months or 12,500 miles from date-of-first-use or demo date, whichever occurs first. Covera
Alignment: Technical Service BulletinsAlignment - Specifications In Degrees

REF.: SUSPENSION
NO.: SU003-96
DATE: MARCH 29, 1996
MODEL: ALL MODELS
1996 MY WHEEL ALIGNMENT SPECIFICATIONS



For your reference listed are the alignment specifications for all 1996 model year vehicles.
> Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications
Alignment: SpecificationsAlignment Specifications
ALIGNMENT SPECIFICATIONS
FRONT
Camber, Caster, Steering Axis Inclination
Toe-In
REAR
Camber
Toe-In
> Steering and Suspension > Alignment > System Information > Specifications > Alignment Specifications > Page 3292
> Steering and Suspension > Alignment > System Information > Specifications > Page 3293
Alignment: Tools and Equipment

Equipment
Tire pressure gaugeDial indicator with magnetic baseWheel balancer

> Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Front
> Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications > Front > Page 3299
> Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications
Power Steering Fluid: Specifications

GENERAL SPECIFICATIONS
Power Steering Fluid ........................................................................................................................................................
> Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Gear/Wheel Removal With SRS
Steering Gear: Technical Service BulletinsSteering - Gear/Wheel Removal With SRS

REF.: STEERING
NO.: STOO1-96
DATE: MAY 17, 1996
MODELS: ALL MODELS
STEERING GEAR/STEERING WHEEL REMOVAL & INSTALLATION
Any time the steering gear is removed on a vehicle equipped with an SRS airbag, the steering wheel must also be remo
REQUIRED STEPS FOR STEERING GEAR REMOVAL AND INSTALLATION:
Removal:
^ Place front wheels facing straight ahead.
^ Remove the steering wheel pad.
^ Remove the steering wheel.
Installation:
^ Center the spiral cable.
^ Install the steering wheel.
^ Install the steering wheel pad.
STEERING GEAR/STEERING WHEEL REMOVAL PROCEDURES:
Follow the steps below to remove the steering wheel from the vehicle.
1. Place front wheels in the straight ahead position.
2. With ignition switch in lock position, disconnect the negative terminal of the battery.
3. Remove Steering wheel pad.
NOTICE:
If the airbag connector is disconnected with the ignition switch at "ON" or "ACC", a "Diagnostic Trouble Cod
Never use airbag parts from another vehicle. When replacing parts, replace with new parts.
a. Remove the steering wheel lower cover.

> Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Steering - Gear/Wheel Removal With SRS > Page 3312

b. Using a torx socket wrench, loosen the torx screws until the groove along the screw circumference catches
c. Pull the wheel pad away from the steering wheel and disconnect the airbag connector. (See Fig. 2)
CAUTION:
When storing the wheel pad, keep the upper surface of the pad facing up.
Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the airbag wiring harness.
4. Remove the steering wheel.
a. Disconnect the spiral cable connector.
b. Remove the wheel set nut.

c. Place match marks on the wheel and steering main shaft. (See Fig. 3)

d. Using the appropriate SST, remove the wheel. SST 09950-50010 or 09609-20011 or suitable substitute.
For further disassembly of the steering column, refer to the Steering (SR) section of the Repair Manual.
STEERING GEAR/STEERING WHEEL INSTALLATION PROCEDURES:
Follow the steps below to install the steering wheel.
2. Center spiral cable.
a. Turn the cable counterclockwise by hand until it becomes harder to turn.
b. Then rotate the cable clockwise about 2.5 or 3 turns to align the marks. (See Fig. 4)
3. Install the steering wheel.
a. Align the match marks on the wheel and steering main shaft.
b. Temporarily tighten the wheel set nut.
c. Connect the spiral cable connector.
4. Bleed Power Steering System (when applicable).
5. Check steering wheel center point.
6. Torque steering wheel set nut. See the applicable vehicle's repair manual for the torque specification.
7. Install and center steering wheel pad.
NOTICE:
Make sure the pad is centered and installed to the specified torque.
If the pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad w
When installing the pad, take care that the wiring does not interfere with other parts and is not pinched between other p
a) Connect the airbag wiring connector.
b) Install the pad after confirming that torx screws are in the screw case.

c) Using a torx socket, torque the screws to the specification in the vehicle's Repair Manual. (See Fig. 5)
d) Install the steering wheel lower cover.
SST (SPECIAL SERVICE TOOLS):

OR USE:

RECOMMENDED TOOLS AND NECESSARY EQUIPMENT:
EQUIPMENT: Torque Wrench
LUBRICANT: ATF DEXRON II or III

Steering Gear: Technical Service BulletinsSteering - Gearbox Removal Precautions

STEERING
ST002-98
May 22, 1998
Title:STEERING GEAR REMOVAL/REPLACEMENT
Models:All Models equipped with SRS Airbag
IntroductionThe following information is provided to supplement the Repair Manual procedure for removing/installing
CAUTION:
When the intermediate shaft is disconnected and the steering wheel is turned freely, the SRS spiral cable may be bro
After working on SRS/Steering components, always check the operation of the SRS Warning Light. Refer to the appro
Affected VehiclesTercel, Paseo, Corolla, MR2, Celica, Camry, Avalon, Supra, Previa, Sienna, RAV4, 4Runner, Tacom
Repair Procedure
1. Position the front wheels facing straight ahead.
Figure # 1
2. Using the driver's seat belt, set the steering wheel so that it does not turn (see Fig. 1).
Figure # 2
3. Paint match marks on the intermediate shaft and control valve shaft (see Fig. 2).
4. Remove the intermediate shaft retaining bolt and disconnect the intermediate shaft (see Fig. 2).

> Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering Wheel Nut - Torque Standardization
Steering Wheel: Technical Service BulletinsSteering Wheel Nut - Torque Standardization

STEERING
ST001-01
February 16, 2001
Title:STEERING WHEEL NUT SERVICE SPECIFICATION
Models:All Applicable Models
Introduction
To make the steering wheel installation procedure similar for all models. the steering wheel nut tightening torque has b
> Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Steering Wheel Nut - Torque Standardization > Page 3322

Service Information
Steering Wheel: Technical Service BulletinsSteering - Gear/Wheel Removal With SRS

REF.: STEERING
NO.: STOO1-96
DATE: MAY 17, 1996
MODELS: ALL MODELS
Removal:
Installation:
NOTICE:


CAUTION:
NOTICE:


NOTICE:


OR USE:


> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Steering/Suspension - Ball Joint Inspection
Ball Joint: Technical Service BulletinsSteering/Suspension - Ball Joint Inspection
PRODUCT GENERAL INFORMATIONPG027-02
December 4, 2002
Title:SUSPENSION BALL JOINT INSPECTION
Models:See Applicable Models
Introduction
This bulletin describes the inspection method and free play specification figures for suspension ball joints. The on-vehi
Applicable Vehicles
> Steering and Suspension > Suspension > Ball Joint > Component Information > Technical Service Bulletins > Steering/Suspension - Ball Joint Inspection > Page 3333




Inspection Information
On-Vehicle Inspection
NOTE:
^ Be sure to check the table for the applicable inspection type based on the vehicle model.
^ Refer to the table for the standard free play values.

1. Inspect Lower Ball Joint Free Play

A. Move the hub up and down by hand (most models with wishbone suspension):
a. Remove the tire.
b. Install the 2 lug nuts.
c. Inspect the free play while moving the lug nuts up and down at a force of 67 lbf (294 N, 30 kgf).
B. Move the lower arm using a lever (some models with double wishbone type suspension):
a. Lift up the vehicle.
b. Place the tip of the lever to the wheel and inspect the free play while moving the lower arm up and do
C. Move the lower arm by hand (all models with strut type suspension and some models with wishbone type s
a Lift up the vehicle.
b. Inspect the free play while moving the lower arm up and down at a force of 67 lbf (294 N, 30 kgf).
2. Inspect Upper Ball Joint Free Play

A. Move the upper arm by hand (models with the LOWER control arm linked by a torsion bar, and all models
a. Remove the front tire.
b. Inspect the free play while moving the upper arm up and down at a force of 67 lbf (294 N, 30 kgf).
B. Move the tire with a lever (models with the UPPER control arm linked by a torsion bar).

a. Lift up the vehicle.
b. Place the lever under the tire, and inspect the tree play while lifting the tire using a wooden stick, etc.
3. Inspect the Suspension Arm Ball Joint Free Play
A. Lift up the vehicle
B. Inspect the free play while moving the control arm by hand.
(Reference)Free Play Inspection Method (Gauge Installation)
^ Position the dial gauge between the arm (upper or lower) and the knuckle, and measure free play.
(This illustration shows how to measure free play for vehicles with double wishbone type suspension with coil sprin
4.
Inspect Ball Joint Dust CoverCheck for cracks and grease leaks on the dust cover (boots).
Turning Torque Inspection
Inspect Ball Joint Turning Torque

Move the stud back and forth 5 times, and then turn the stud continuously at 3-5 seconds per turn, and measure the turn
HINT:
Refer to the table for standard values for the turning torque.
> Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Front
> Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications > Front > Page 3343
> Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Front
> Steering and Suspension > Suspension > Rear Knuckle > Component Information > Specifications > Front > Page 3348
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Front > Page 3353
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 3354
Suspension Strut / Shock Absorber: Testing and Inspection
INSPECTION
-
Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front
Suspension Strut / Shock Absorber: Service and RepairFront

Fig. 2 Front Suspension Strut Assembly.
1. Remove front wheel and disconnect ABS wire harness clamp if vehicle is equipped with ABS.
2. Fig. 2.Disconnect brake hose from shock absorber,
3. Remove three nuts on upper side of strut in engine compartment.
> Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 3357

4. Remove two nuts and bolts from lower side of strut assembly.
5. Remove strut assembly.
6. Reverse procedure to install. Tighten to specifications.
Suspension Strut / Shock Absorber: Service and RepairRear
Removal and Installation

REAR SHOCK ABSORBER REMOVAL
1. Fixed Type: REMOVAL REAR SEAT
Separate Type: REMOVAL REAR SIDE SEAT BACK
2. REMOVE REAR WHEEL
103 N.m (1,050 kgf.cm, 76 ft.lbf)Torque:

3. REMOVE BRAKE HOSE FROM SHOCK ABSORBER
4. DISCONNECT ABS SPEED SENSOR (w/ABS) AND STABILIZER BAR LINK FROM SHOCK ABSORBER
5.5 N.m (58 kgf.cm. 49 in..lbf)

44 N.m (450 kgf.cm, 33 ft.lbfTorque:ABS wire: Stabilizer bar link:
5. REMOVE SHOCK ABSORBER AND COIL SPRING

2(a) Loosen the nuts on the lower side of shock absorber.
INSTALLATION HINT: Coat the nuts' thread with engine oil.
142 N.m (1,450 kgf.cm. 105 ft.lbf)
39 N.m (400 kgf.cm, 29 ft.lbf 2

Torque: (b) Support the rear axle carrier with a jack.(c) Remove the 3 nuts of suspension upper support. Torque:
Disassembly and Assembly
REAR SHOCK ABSORBER DISASSEMBLY

REMOVE COIL SPRING
(a) Install a bolt and 2 nuts to the bracket at the lower portion of the shock absorber and secure it in a vise.(b) Usi
NOTICE Do not use an impact wrench. It will damage the SST.
(c) Using SST to hold the suspension upper support, remove the nut. SST 09729-22031(d) Remove these parts:
- Collar
- Suspension upper support
- Coil spring
- Spring bumper
- Lower insulator
REAR SHOCK ABSORBER ASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK ABSORBER2. INSTALL SPRING BUMPER TO PISTON R
(a) Using SST. compress the coil spring. SST 09727-30020
NOTICE: Do not use an impact wrench. It will damage the SST.
(b) Install the coil spring to the shock absorber.
HINT Fit the lower end of the coil spring into the gap of the lower seat.
4. INSTALL SUSPENSION UPPER SUPPORT
(a) Align the suspension upper support with the shock absorber lower bracket, as shown.

(b) Install the collar to the piston rod.(c) Using SST to hold the suspension upper support,install a new nut. SST 0
49 N.m (500 kgf.cm, 30 ft.lbfTorque:
(d) Remove the SST.
HINT: After removing SST, again check the direction of the suspension upper support.
Suspension Strut / Shock Absorber: Service and RepairDisposal
REAR SHOCK ABSORBER DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill. make a hole in the cylinder, as shown to remove the gas inside.
CAUTION: The gas coming out is harmless, but be careful of chips which may fly up when drilling.
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Front
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Front > Page 3367
> Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 3368



5. w/ABS:



1. Remove lock nut.
2. Remove axle hub.

> Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drive Axles - Front Hub Nut Replacement
MARCH 6, 1998
Introduction
NOTE:
Affected Vehicles
Parts Information

> Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front
> Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 3379
> Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > SU00696 > Nov > 96 > Drivetrain - Sq
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Steering and Suspension > Suspension > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > SU00696 > Nov > 96 > D
Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update
Wheels: Technical Service BulletinsWheels - Balance Adapter Kit Update

Ref: SUSPENSION
No.: SU002-96 (REVISED)
Date: SEPTEMBER 6, 1996
Model: ALL MODELS
Title: WHEEL BALANCE ADAPTER KIT
To improve the accuracy of Dynamic Off-Car wheel balancing on all OEM Toyota five and six lug wheels, a precision
NOTE:
Tires that have nylon belts must be warmed-up sufficiently by driving 4 to 5 miles at 45 m.p.h. before balancing. Th
BALANCE PROCEDURE:
The Haweka Flange Plate uses the wheel lug holes and a centering cone to center the wheel on the balancer arbor as the
1.
Use the centering cone and flange plate combination on all five and six lug steel and alloy Toyota wheels. On fou
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update > Page 3398

2.
Verify that the centering cone fits inside the wheel center as well as inside the balance machine hub (see Figure 2
3. Always install the spring and centering cone toward the back side of the wheel (see Fig. 3).
For additional wheel balancer accessories, refer to the latest Toyota Approved Dealer Equipment catalog (P/N 00451-8
To place an order, please call Toyota Approved Dealer Equipment at 1 (800) 368-6787.
> Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Balance Adapter Kit Update > Page 3399
Wheels: Technical Service BulletinsWheels - Full Wheel Cover Application Caution
BODYBO028-97
October 3, 1997
Introduction
CAUTION:
Affected Vehicles
Parts Information
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Front > Page 3404
> Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 3405



5. w/ABS:



1. Remove lock nut.
2. Remove axle hub.

> Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Technical Service Bulletins > Wheels - Full Wheel Cover Application Caution
Wheel Cover: Technical Service BulletinsWheels - Full Wheel Cover Application Caution
BODYBO028-97
October 3, 1997
Introduction
CAUTION:
Affected Vehicles
Parts Information
> Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Technical Service Bulletins > Drive Axles - Front Hub Nut Replacement
MARCH 6, 1998
Introduction
NOTE:
Affected Vehicles
Parts Information

> Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front
> Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications > Front > Page 3420
> Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications

Wheel Fastener .....................................................................................................................................................................
> Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Seal: > SU00696 > Nov >
From Front Axle Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Steering and Suspension > Wheels and Tires > Wheel Seal > Component Information > Technical Service Bulletins > Customer Interest for Wheel Seal: > SU00696 > Nov > 96 > Drivetra
Hub
Ref.: SUSPENSION
No.: SU006-96
Model: COR
JT2*A02E*T0110035

> Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations

> Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 3441



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Compressor HVAC > Component Information > Technical Service Bulletins > A/C - Compressor Maintenance for Stored Vehicles
Compressor HVAC: Technical Service BulletinsA/C - Compressor Maintenance for Stored Vehicles
REF.: HEATING & AIR CONDITIONING
NO.: AC002-96
DATE: MAY 31, 1996
MODEL: ALL MODELS
A/C COMPRESSOR MAINTENANCE FOR STORED VEHICLES
When a vehicle is stored for a long period, the volume of oil in the A/C compressor may decrease due to oil flow into t
If the A/C system is turned on at high engine RPM after a long storage period, A/C compressor damage may result.
To minimize the possibility of damage to the A/C compressor while storing a vehicle, perform the following recommen
RECOMMENDED PROCEDURE FOR A/C COMPRESSOR LUBRICATION:
1. Turn off A/C and blower switches prior to starting engine.
2. Start and warm-up engine until engine speed drops below 1,000 RPM.
3. Turn on the A/C system using the following settings:
^ A/C switch: On
^ Blower Speed: High
^ Engine speed: Below 1,000 RPM
4. Keep A/C on with engine idling for 30 seconds.
5. Turn off A/C system and stop engine.

> Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations

> Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 3453



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations

> Heating and Air Conditioning > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 3461



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Control Module HVAC > Component Information > Testing and Inspection


conditions:-
- ONBlower switch

conditions:-
- Blower switch HI
- ONA/C switch
> Heating and Air Conditioning > Control Module HVAC > Component Information > Testing and Inspection > Page 3469
AMPLIFIER REMOVAL
2. Remove Amplifier
> Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > AC00297 > May > 97 > A/C - Evapo
AC00297Technical Service Bulletin #
A/C - Evaporator Odor
May 9, 1997
Title:AIR CONDITIONING EVAPORATOR ODOR
Models:All Models
IntroductionA musty odor may be emitted from the air conditioning system of some vehicles which are usually operate
1. Blockage of the evaporator housing drain pipe, resulting in the build up of condensate.
2. Microbial growth in the evaporator, arising from dampness in the evaporator housing where the cooling air flow
To address excessive air conditioning evaporator odor, check the evaporator housing drain pipe for blockage. If no prob
Affected Vehicles^
While this procedure may be used on any Toyota vehicle, this bulletin gives details Vehicles specifically for the AE
Tools & Materials
CAUTION:
Wear safety glasses, protective mask, and gloves while working with the freshener.
Table of Contents
General Procedure
> Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > AC00297 > May > 97
> A/C - Evaporator Odor > Page 3478

1. Preparation of freshener solution:
(a) Invert freshener container and shake vigorously for 30 seconds.
(b) Mix 3.4 fl. oz. of freshener (1 container) with 30 fl. oz. to make 1 qt. of solution.
2. Drying the evaporator:
^ Dry the evaporator for 10 minutes with the following settings:
AC: Off
Air Outlet: Foot
Mode: Recirc.
Blower High
Temp: Max Warm
3. Evaporator Treatment Preparation:
(a) Ensure availability of 3045 psi compressed-air to be used with spray gun for application of freshener.
(b) Place a tray under the evaporator housing drain hose to collect used cleaning solution.
(c) Place shop cloth under the evaporator housing in the vehicle to prevent cleaning solution from dripping ont
4. Vehicle Preparation: See specific model section.
5. Evaporator treatment:
(a) Set HVAC mode as follows:
AC: Off
Air Outlet: Face

Mode: Fresh
Blower: High
Temp: Max Warm
Windows Open
(b)
Insert spray nozzle into the filter inlet and spray the entire quantity (1 qt.) of freshener solution into the eva
(c) Turn the blower OFF.
6. Reinstallation of Parts.
7. Completion of Treatment.
(a) Dry the evaporator for 30 minutes with the following settings:
AC: Off
Air Outlet Foot
Mode: Recirc.
Blower: High
Temp: Max Warm
Windows: Closed
(b)
If vehicle still has alcohol smell, open windows for ventilation. Do not turn on the AC switch until the evap
CAUTION
Do not get Into the vehicle during this drying operation.
Camry ( SXV/VCV10)
1. Removal of parts.
(a) Pull down the carpet from the center console as indicated by the bigger arrow in the illustration.

(b) Remove the plate on the side of the heater unit using steps (1) and (2), indicated with bigger arrows to show
CAUTION:
1. Do not bend the cable.2. The plate will be reused.
(c) Remove the blower resistor.
2. Cleaning the Evaporator.
^ Follow the general procedures at the beginning of this bulletin.
3. Reinstallation of parts.
(a) Reinstall the plate on the side of the heater unit using steps (1) and (2), indicated with bigger arrows to show
CAUTION:
Confirm that the plate is secure.
(b) Restore the carpet to its original position taking care not to bend the cable.
Corolla (AE100)

(a) Remove the scuff plate from the passenger side door sill.
(b) Open the glove box door and temporarily remove the Air Bag Harness Cover as shown in the illustration.
CAUTION:
Do not disconnect the Air Bag Harness.
(c) Pass the cover up through the hole.
CAUTION:
Take care not to pinch the Air Bag Harness when reinstalling the cover.
(d) Remove the glove box.

(e) Remove the passenger side air duct.
(f) Remove the blower resistor to allow access for the spray nozzle (insert at bigger arrow).
^ Reinstall the parts in the reverse order of removal described in step 1.
CAUTION:
Make sure that the three guides of glove box are Inserted back into the three holes as shown in the Illustration
CAUTION:
Take care not to pinch the Air Bag Harness when reinstalling the glove box.

Avalon (MCX10)
(a) Remove lower finish panels.

(b) If manual AC remove blower resistor.
(c) If auto-AC remove power transistor.

Cressida (MX83)

(a) Remove glove box.
(b) Remove power transistor.

Celica (AT180/200), (ST184/204)

(b) Remove blower resistor.
^ Reinstall the parts in The reverse order of removal described in step 1.

Supra (JZA80)
(a) Remove the glove box, side air duct and the ECM.
(b) Remove evaporator cover.

Tercel/Paseo (EL42/44/53)

2. Cleaning the Evaporation

Previa (TCR10/20)
(a) Remove air duct and blower motor.


Land Cruiser (FZJ80)
(a) Remove glove compartment door.

MR2, T100, Truck, Tacoma, 4RUNNER, Other

^ Remove the blower motor.
^ Reinstall the blower motor.

> Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > AC00297 > May > 97 >
May 9, 1997
Models:All Models
Affected Vehicles^
Tools & Materials
CAUTION:
Table of Contents
General Procedure
> Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: >
AC00297 > May > 97 > A/C - Evaporator Odor > Page 3494

AC: Off
Air Outlet: Foot
Mode: Recirc.
Blower High
Temp: Max Warm
AC: Off
Air Outlet: Face

Mode: Fresh
Blower: High
Temp: Max Warm
Windows Open
(b)
AC: Off
Air Outlet Foot
Mode: Recirc.
Blower: High
Temp: Max Warm
Windows: Closed
(b)
CAUTION
Camry ( SXV/VCV10)

CAUTION:
CAUTION:
Corolla (AE100)

CAUTION:
CAUTION:

CAUTION:
CAUTION:

Avalon (MCX10)


Cressida (MX83)


Celica (AT180/200), (ST184/204)


Supra (JZA80)



Previa (TCR10/20)





> Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Removal and Installation
Evaporator Case: Service and RepairRemoval and Installation

COOLING UNIT REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
INSTALLATION HINT: Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage age of refrigerant.
Specified amount: 700 50 g (24.69 1.76 oz.)
2. REMOVE THESE PARTS:
(a) Front door scuff plate (b) Glove compartment parts (c) Duct heater to register No. 4
3. DISCONNECT SUCTION AND LIQUID TUBES

Loosen the 2 union nuts and disconnect the both tubes.
Torque:
Liquid tube:
14 N.m (140 kgf.cm, 10 ft.lbf)
Suction tube:
32 N.m (330 kgf.cm, 24 ft.lbf)
NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system.
INSTALLATION HINT: Lubricate 2 new O-rings with compressor oil and install the tubes.
4. REMOVE COOLING UNIT

(a) Disconnect the connectors.(b) Remove the 2 nuts, 3 screws and cooling unit.
COOLING UNIT INSTALLATION
> Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Removal and Installation > Page 3507
Evaporator Case: Service and RepairDisassembly and Reassembly
COOLING UNIT DISASSEMBLY
1. REMOVE THESE PARTS:
(a) Wire harness(b) Blower resistor(c) Drain hose
2. SEPARATE UPPER AND LOWER UNIT CASES
(a) Using a knife, cut off each packing.(b) Remove the 4 screws, 3 clips and separate the upper and lower unit cas
3. REMOVE EVAPORATOR FROM LOWER UNIT CASE
ASSEMBLY HINT: If evaporator was replaced, add compressor oil to compressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil:
ND-OIL 8 or equivalent
4. REMOVE THERMISTOR FROM EVAPORATOR
5. REMOVE EXPANSION VALVE

Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator.
ASSEMBLY HINT: Lubricate 4 new O-rings with compressor oil and install the tubes.
COOLING UNIT ASSEMBLY

Assembly is in the reverse order of disassembly.
> Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > AC00297 > May > 97 > A/C - Evapo
May 9, 1997
Models:All Models
Affected Vehicles^
Tools & Materials
CAUTION:
Table of Contents
General Procedure
> Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > AC00297 > May > 97

AC: Off
Air Outlet: Foot
Mode: Recirc.
Blower High
Temp: Max Warm
AC: Off
Air Outlet: Face

Mode: Fresh
Blower: High
Temp: Max Warm
Windows Open
(b)
AC: Off
Air Outlet Foot
Mode: Recirc.
Blower: High
Temp: Max Warm
Windows: Closed
(b)
CAUTION
Camry ( SXV/VCV10)

CAUTION:
CAUTION:
Corolla (AE100)

CAUTION:
CAUTION:

CAUTION:
CAUTION:

Avalon (MCX10)


Cressida (MX83)


Celica (AT180/200), (ST184/204)


Supra (JZA80)



Previa (TCR10/20)





> Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > AC00297 > May > 97 >
May 9, 1997
Models:All Models
Affected Vehicles^
Tools & Materials
CAUTION:
Table of Contents
General Procedure
> Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: >

AC: Off
Air Outlet: Foot
Mode: Recirc.
Blower High
Temp: Max Warm
AC: Off
Air Outlet: Face

Mode: Fresh
Blower: High
Temp: Max Warm
Windows Open
(b)
AC: Off
Air Outlet Foot
Mode: Recirc.
Blower: High
Temp: Max Warm
Windows: Closed
(b)
CAUTION
Camry ( SXV/VCV10)

CAUTION:
CAUTION:
Corolla (AE100)

CAUTION:
CAUTION:

CAUTION:
CAUTION:

Avalon (MCX10)


Cressida (MX83)


Celica (AT180/200), (ST184/204)


Supra (JZA80)



Previa (TCR10/20)





> Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 3543
Evaporator Core: Testing and Inspection

EVAPORATOR INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE

If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES

Repair as necessary.
> Heating and Air Conditioning > Heater Core > Component Information > Service and Repair
Heater Core: Service and Repair

No R&R for Heater Core in OE manual. Refer to Instrument Panel R&R.
> Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Alternative Refrigerants and Retrofits
Refrigerant: Technical Service BulletinsA/C - Alternative Refrigerants and Retrofits

Ref.: HEATING & AIR CONDITIONING
No.: AC003-96
Model: ALL MODELS
Title: ALTERNATE REFRIGERANTS AND A/C RETROFIT
The E.P.A. has officially banned the manufacture of Refrigerant 12 (Freon) after January 1, 1996. As a result, surplus s
This uncertainty about the availability of R-12 has caused significant concerns for Toyota dealers when servicing HVA
ALTERNATE REFRIGERANTS:
Previously, the E.P.A. has endorsed other alternative refrigerants. These endorsements, combined with the uncertain fu
^ Poor system performance and leak detection capabilities.
^ Contamination of R-12 and R-134a during refrigerant recovery and recycling.
Recently the E.P.A. released a statement clarifying that approval of alternative refrigerants relates only to the toxicolog
TOYOTA MOTOR SALES, U.S.A. ENDORSES THE USE OF R-134A AS THE ONLY ACCEPTABLE ALTERNA
R-12 AVAILABILITY:
RETROFIT ISSUES:
Toyota has completed development of retrofit parts for all later model Toyota vehicles - using R-12 refrigerant. These p
The parts necessary for a typical retrofit will generally include:
^ Receiver Dryer
^ 0-Rings
^ Fittings
^ Labels
It is estimated that existing R-12 supplies will meet market demand in 1996. Beyond that, Toyota will supply R-12 to i
^ Oil
A TSB outlining retrofit procedures will be released when the retrofit kits become available.
For additional information, contact the Toyota Environmental Assistance Network Hotline at 1-800-542-3914.
> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications
Refrigerant: Capacity Specifications
Charge Volume 24.69 +/- 1.76 oz (US)

> Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 3553
Refrigerant: Fluid Type Specifications
Type R134a
> Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications
Refrigerant Oil: Capacity SpecificationsOil Capacity

Oil Capacity
When Replacing Receiver Add 20 cc
When Replacing Condenser Add 40 cc
When Replacing Evaporator Add 40 cc
When Replacing Compressor Add120 cc

> Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3558
Refrigerant Oil: Fluid Type Specifications
Type ND-OIL 8
> Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations

> Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 3563



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations

> Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 3571



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations

> Heating and Air Conditioning > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Locations > Page 3579



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Testing and Inspection


conditions:-
- ONBlower switch

conditions:-
- Blower switch HI
- ONA/C switch
> Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Testing and Inspection > Page 3587
AMPLIFIER REMOVAL
2. Remove Amplifier
> Heating and Air Conditioning > Sensors and Switches - HVAC > System Information > Technical Service Bulletins > A/C - Sensor Inspection Procedures
Sensors and Switches - HVAC: Technical Service BulletinsA/C - Sensor Inspection Procedures
Title:SENSOR INSPECTION FOR AIRCONDITIONING SYSTEM
Models'89 - Current All Models
December 16, 2004
Introduction
This service bulletin contains inspection procedures to more precisely confirm proper operation of the following tempe
^ Room Temperature Sensor
^ Ambient Temperature Sensor
^ Air Duct Sensor
^ Evaporator Temperature Sensor
^ Solar Sensor Room Humidity Sensor
Applicable Vehicles
All 1989 - Current model year Toyota vehicles.
Inspection Procedure
1. Inspect Room Temperature Sensor.

> Heating and Air Conditioning > Sensors and Switches - HVAC > System Information > Technical Service Bulletins > A/C - Sensor Inspection Procedures > Page 3592

A. Measure the sensor resistance.
NOTE:
HINT:
2. Inspect Ambient Temperature Sensor.
NOTE:

HINT:
3. Inspect Air Duct Sensor.
A. Measure the sensor resistance according to the table and graph (specification).
NOTE:
HINT:
4. Inspect Evaporator Temperature Sensor.


Select the appropriate graph (specification) using the table.
NOTE:
Please inspect the sensors for model years not indicated by this bulletin, according to the instructions in the applicab


NOTE:
^ Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the se
HINT:
5. Inspect Solar Sensor.

Four types of solar sensors are used on Toyota vehicles depending on the vehicle specifications. The inspection p
Procedure A:

NOTE:
^
Terminal 1 of the sensor is always on the right, when the lock is facing up. When using an analog tester, c
HINT:
Standard:
Procedure B:

NOTE:
When using an analog tester, connect the positive (+) lead to terminal 3 and negative (-) lead to terminal 2 of
HINT:
Standard:
Procedure C:
b. Measure the voltage between terminals TSR (+) and CLTE (-) of the connector under the following conditi
HINT:

Standard:

c. Measure the voltage between terminals TSL (+) and CLTE (-) of the connector under the following conditi
HINT:
Standard:
Procedure D:

b. Using the tester, measure the voltage between terminals TSD (+) and CLTE (-) of the connector under the f
HINT:

Standard:
6. Inspect Room Humidity Sensor.
Measure the humidity and output voltage of the humidity sensor when the sensor is installed on the vehicle and th
HINT:
For the inspection procedure of the room temperature sensor, refer to "Room Temperature Sensor Inspection Proced
A. Turn the ignition switch to the ON position.
B. Measure the voltage between terminal VO (3) and GND (2) of the room humidity sensor.
C.
Measure the humidity and voltage when the room temperature (humidity sensor position) is 77F (25C). Acc
> Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Technical Service Bulletins > Electrical - SRS And HV Wiring Repairs
Air Bag Harness: Technical Service BulletinsElectrical - SRS And HV Wiring Repairs
SECTION: ELECTRICAL
BULLETIN # 156
DATE: AUGUST 2007
> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Steering - Gear/Wheel Removal With SR
Clockspring Assembly / Spiral Cable: Technical Service BulletinsSteering - Gear/Wheel Removal With SRS
REF.: STEERING
NO.: STOO1-96
DATE: MAY 17, 1996
MODELS: ALL MODELS
Removal:
Installation:
NOTICE:

> Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Technical Service Bulletins > Steering - Gear/Wheel
Removal With SRS > Page 3616

CAUTION:
NOTICE:


NOTICE:


OR USE:


> Restraint Systems > Air Bag Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - OCS System Initialization
DATE: MARCH 2010
NOTE:
> Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - OCS System Initialization
DATE: MARCH 2010
NOTE:
> Restraint Systems > Relays and Modules - Restraint Systems > Seat Occupant Classification Module - Air Bag > Component Information > Technical Service Bulletins > Restraints - OCS
DATE: MARCH 2010
NOTE:
> Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Restraint Systems > Seat Belt Systems > Child Restraint > Component Information > Technical Service Bulletins > Child Restraint - Seat Top Strap Installation
BO010-02Technical Service Bulletin #
Child Restraint - Seat Top Strap Installation
BODYBO010-02
May 24, 2002
Title:CHILD RESTRAINT SEAT TOP STRAP BRACKET INSTALLATION
Models:'83 - '00 All Models
Introduction
Child restraint seat top strap bracket installation procedures are provided to supplement the Owner's Manual. Beginning
NOTE:
^
The top strap brackets can only be installed on vehicles that have nuts welded in place by the factory. The locati
1983 - 2000
Applicable model year vehicles, all models.
Vehicles^
Parts Information
The child restraint seat top strap assembly is not available as a service part. Contact the child restraint seat manu
Installation Procedure/Reference Information

> Restraint Systems > Seat Belt Systems > Child Restraint > Component Information > Technical Service Bulletins > Child Restraint - Seat Top Strap Installation > Page 3641

Child Restraint Seat Top Strap Bracket Installation
Obtain the exact year and vehicle model Toyota Owner's Manual before beginning installation.
1.
Confirm with the customer which seat location(s) they will be installing the child restraint seat. The Owner's Man
NOTE:
Determine which kit parts are needed for each specific child seat location, by referring information in this bulletin.
2.
Remove a 20mm diameter area of the carpet or trim material above the bracket mounting location. In some vehic
3.
If a 5mm or 15mm spacer is specified, remove the red lock washer from the Bracket Sub-Assembly (P/N 73709-1

4.
Install the bracket assembly, according to the directions in the Owner's Manual. Tighten the bolt to 16.5 - 24.7 N-
^ Assure the top strap is attached to the child seat, according to the child seat manufacturer's instructions.
^ Assure the child seat is installed in the vehicle according to the Toyota Owner's Manual (seat section).
Owner's Manual Installation Reference Information







The illustrations shown contain a reference information chart. This chart contain.
^
Owner's Manual page(s) that provide the illustration showing available top strap bracket location(s). The informatio
Installation notes, such as bracket spacer sizes for each specific child seat location.
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > BO026-01 > Oct > 01 > Seat Belts - Shoulder Anchor Ta
Seat Belt: Customer InterestSeat Belts - Shoulder Anchor Tape Set
BODYBO026-01
October 19, 2001
Title:SHOULDER BELT ANCHOR TAPE SET
Models:All Applicable Avalon, Camry, Corolla, Previa, & Sienna
Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor
1996 - 1999
Applicable model year Avalon vehicles.
Vehicles^
^ 1996 - 2001 model year Camry vehicles.
^ 1993 - 2001 model year Corolla vehicles.
^ 1996 - 1997 model year Previa vehicles.
^ 1998 - 2001 model year Sienna*1 vehicles.
*1 Except rear seat belt.
Parts Information
Applicable warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 m
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
1. CLEAN SHOULDER BELT ANCHOR
NOTE:
^ Do not install the tape when the vehicle temperature is below the freezing point.
^ Do not re-use removed fluorocarbon resin tape.
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Customer Interest: > BO026-01 > Oct > 01 > Seat Belts -
Shoulder Anchor Tape Set > Page 3657

A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration.
HINT:
Preventing the seat belt from retraction with a clip will make the following work easier.
B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the a
C.
Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by movi
NOTE:
Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly.
2. INSTALL FLUOROCARBON RESIN TAPE

A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration.

NOTE:
Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each
B.
By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Ma
C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outs
D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outs
NOTE:
^ Be sure to affix the fluorocarbon tape securely along all edges.
^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape.
E. Remove the clip.

F.
By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocar
NOTE:
Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure.
NOTE:
If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the se
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > SB0258-08 > Sep > 08 > Rest
Stopper Replacement
Seat Belt: All Technical Service BulletinsRestraints - Seat Belt Tongue Plate Stopper Replacement
T-SB-0258-08
September 2, 2008
Seat Belt Tongue Plate Stopper Replacement
Service CategoryVehicle Interior
SectionSeat Belt
MarketUSA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. BO017-07.
^ Applicability has been updated to include 2008 model year vehicles.

TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content o
Introduction
For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > SB0258-08 >
Sep > 08 > Restraints - Seat Belt Tongue Plate Stopper Replacement > Page 3665

APPLICABLE WARRANTY
^
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,00
^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Parts Information
Repair Procedure
1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape.
2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers.
NOTE
Be careful not to damage the webbing, since this may compromise the safety of this seatbelt.
CAUTION
Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MU
^ The webbing is cut, frayed, worn, or damaged.
^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred)

Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to dama
3. Install the NEW tongue plate stopper
A. Install a NEW tongue plate stopper in the hole of the webbing.
NOTE
Be sure to install the stopper in the correct direction as shown in the illustration.
B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp.
NOTE
To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to mode
HINT
Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each o

CAUTION
For this procedure, do not use pliers. They may damage the webbing.
C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5 & 6

D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is fir
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > BO026-01 > Oct > 01 > Seat
Seat Belt: All Technical Service BulletinsSeat Belts - Shoulder Anchor Tape Set
BODYBO026-01
October 19, 2001
Title:SHOULDER BELT ANCHOR TAPE SET
Models:All Applicable Avalon, Camry, Corolla, Previa, & Sienna
Introduction To assist customers in preventing particle buildup and preserve the appearance of the shoulder belt anchor
1996 - 1999
Applicable model year Avalon vehicles.
Vehicles^
^ 1996 - 2001 model year Camry vehicles.
^ 1993 - 2001 model year Corolla vehicles.
^ 1996 - 1997 model year Previa vehicles.
^ 1998 - 2001 model year Sienna*1 vehicles.
*1 Except rear seat belt.
Parts Information
Applicable warranty*:
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 m
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
1. CLEAN SHOULDER BELT ANCHOR
NOTE:
^ Do not install the tape when the vehicle temperature is below the freezing point.
^ Do not re-use removed fluorocarbon resin tape.
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > BO026-01 >
Oct > 01 > Seat Belts - Shoulder Anchor Tape Set > Page 3673

A. Pull out the seat belt about 300 mm and attach a clip as shown in the illustration.
HINT:
Preventing the seat belt from retraction with a clip will make the following work easier.
B. Put the Velcro tape (in the parts kit) through the hole of the shoulder belt anchor, brush-shaped side to the a
C.
Pull both ends of the Velcro tape with your hand and shave off the dirt on the shoulder belt anchor by movi
NOTE:
Remove the dirt completely. Otherwise, the fluorocarbon resin tape may not adhere properly.
2. INSTALL FLUOROCARBON RESIN TAPE

A. Place the fluorocarbon resin tape onto the seat belt as shown in the illustration.

NOTE:
Before installation of the fluorocarbon resin tape, it is necessary to pre-release the colored film about 5 mm for each
B.
By pulling up the seat belt, put the fluorocarbon resin tape through the hole of the shoulder belt anchor. Ma
C. Remove the upper side colored film from the fluorocarbon resin tape, and securely affix the tape to the outs
D. Remove the lower side colored film from the fluorocarbon resin tape, and securely affix the tape to the outs
NOTE:
^ Be sure to affix the fluorocarbon tape securely along all edges.
^ Pay attention not to make any wrinkles or slack in the fluorocarbon resin tape.
E. Remove the clip.

F.
By pulling the seat belt up and down several times, as shown in the illustration, securely affix the fluorocar
NOTE:
Affix the fluorocarbon resin tape on the shoulder belt anchor to the other side following the same procedure.
NOTE:
If the seat belt requires cleaning to remove dirt, only use a neutral detergent or lukewarm water to clean. Use the se
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > B095012 > Nov > 95 > Seat B
Seat Belt: All Technical Service BulletinsSeat Belts - Front and Rear Extenders
REF.: BODY
NO.: BO95-012
MODEL: ALL MODELS
SEAT BELT EXTENDER (1987 TO 1996 MODEL YEARS)
A special program is available for individuals who require extra length seat belts. Owners of 1987 through 1996 vehicl
The seat belt extender is available in black only and in lengths of 6", 9", 12", 15" and 18".
Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each 1987 o
The user must visit a Toyota Dealership to have the required measurements made and complete the seat belt extender w
Included are the following 1996 model year updated guides and examples:
Flow ChartSeat Belt Extender Application/Part Number Chart Owner Instruction SheetStatement included in Ow
The dealership service department should complete the affixed Seat Belt Extender Label and review the "owner instruc
To assure utmost owner satisfaction, it is recommended that a dealer designate one person to coordinate all activities re
Due to past sales history, it is recommended that dealers DO NOT stock seat belt extenders due to low demand for the
SEAT BELT EXTENDER (SBE) FLOW CHART:
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > B095012 >
Nov > 95 > Seat Belts - Front and Rear Extenders > Page 3680

SEAT BELT LABEL SAMPLE
1. Owner requests a seat belt extender from the dealer.
2. Dealer verifies need for a seat belt extender and obtains current copy of TSB and copies the worksheet.
3.
Dealer measures the customer and completes the worksheet. Dealer determines the correct part number needed an
4. Dealer receives the seat belt extender and calls customer in to check fit of the part.
5.
If the seat belt extender fit is OK, dealer completes the customer information label on the part, explains usage of
6. Dealer places a copy of the completed worksheet in the customer's records.



FRONT SEAT EXTENDER APPLICATION TABLE
NOTE:
The front lap belt for all '90 Corolla models and the '90 Tercel is the ALR type. Make sure the ALR is locked when


REAR SEAT EXTENDER APPLICATION TABLE
Note:
The extender must not be used for the center rear seat belt on any model.

OWNER INSTRUCTION:
Failure to follow the recommendations indicated below could result in less effectiveness of the seat belt restraint system
1. The seat belt extender must not be used:
(I) By anyone other than for whom it was provided (name recorded on seat belt extender).

(II) In any vehicle and/or seat position other than the one for which it is provided.
2.
To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the buckle-release buttons o
3. When the seat belt extender is provided for rear seat position (with automatic locking retractor), make sure the re
4.
When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps p
5. When not in use, remove the extender and store in the vehicle for future use.
OWNER'S MANUAL TEXT:
SEAT BELT EXTENDER
If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender~is availabl
Please contact your local Toyota dealer so that the dealer can order the proper required length for the extender. Bring th
CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in less eff
Never use the seat belt extender if you can fasten the seat belt without it.
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another pe

To connect the extender to the seat belt, insert the tab into the seat belt buckle so that the "PRESS" signs on the buckle-
You will hear a click when the tab locks into the buckle.
When releasing the seat belt, press on the buckle-release button on the extender, not on the seat belt. This helps prevent
When not in use, remove the extender and store in the vehicle for future use.

SEAT BELT EXTENDER WORKSHEET
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > SB0258-08 > Sep > 08 > Restrain
Replacement
Seat Belt: All Technical Service BulletinsRestraints - Seat Belt Tongue Plate Stopper Replacement
T-SB-0258-08
September 2, 2008
Seat Belt Tongue Plate Stopper Replacement
Service CategoryVehicle Interior
SectionSeat Belt
MarketUSA
Applicability
TSB SUPERSESSION NOTICE
The information contained in this TSB supersedes TSB No. BO017-07.
^ Applicability has been updated to include 2008 model year vehicles.

TSB No. BO017-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content o
Introduction
For situations where only the seat belt stopper is broken a new service part has been developed to eliminate the need to
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > SB0258-08 > Sep
> 08 > Restraints - Seat Belt Tongue Plate Stopper Replacement > Page 3694

APPLICABLE WARRANTY
^
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,00
^ Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Parts Information
Repair Procedure
1. Shift the tongue plate to the upper portion of the tongue plate stopper and temporarily hold it with a clip or tape.
2. Remove any pieces of the original tongue plate stopper in the webbing with a pair of diagonal pliers.
NOTE
Be careful not to damage the webbing, since this may compromise the safety of this seatbelt.
CAUTION
Damaged or weakened seat belts may break in an accident and injure the occupant. The seat belt assembly MU
^ The webbing is cut, frayed, worn, or damaged.
^ It has been used during a severe impact (inspect the label to ensure no impact damage has occurred)

Inspect the entire length of webbing for damage and replace the assembly if needed. Be careful NOT to dama
3. Install the NEW tongue plate stopper
A. Install a NEW tongue plate stopper in the hole of the webbing.
NOTE
Be sure to install the stopper in the correct direction as shown in the illustration.
B. Pinch the tongue plate stopper into the webbing using the tool shown in Figure 3 or use a small "C" clamp.
NOTE
To prevent damage to the plastic tongue plate stopper when using a "C" clamp device, use light to mode
HINT
Press the adjustment screw locating the male and female parts of the tongue plate stopper parallel to each o

CAUTION
For this procedure, do not use pliers. They may damage the webbing.
C. Tighten the c-clamp until the space between its jaws are 4.5 - 5.0 mm (0.18 in. -0.20 in.) Figures 5 & 6

D. Verify the male pin of the tongue plate stopper has deformed evenly in the hole of the female part and is fir
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > B095012 > Nov > 95 > Seat Belts
Seat Belt: All Technical Service BulletinsSeat Belts - Front and Rear Extenders
REF.: BODY
NO.: BO95-012
MODEL: ALL MODELS
SEAT BELT EXTENDER (1987 TO 1996 MODEL YEARS)
A special program is available for individuals who require extra length seat belts. Owners of 1987 through 1996 vehicl
The seat belt extender is available in black only and in lengths of 6", 9", 12", 15" and 18".
Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each 1987 o
The user must visit a Toyota Dealership to have the required measurements made and complete the seat belt extender w
Included are the following 1996 model year updated guides and examples:
Flow ChartSeat Belt Extender Application/Part Number Chart Owner Instruction SheetStatement included in Ow
To assure utmost owner satisfaction, it is recommended that a dealer designate one person to coordinate all activities re
Due to past sales history, it is recommended that dealers DO NOT stock seat belt extenders due to low demand for the
SEAT BELT EXTENDER (SBE) FLOW CHART:
> Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > B095012 > Nov >
95 > Seat Belts - Front and Rear Extenders > Page 3702

SEAT BELT LABEL SAMPLE
2. Dealer verifies need for a seat belt extender and obtains current copy of TSB and copies the worksheet.
3.
Dealer measures the customer and completes the worksheet. Dealer determines the correct part number needed an
4. Dealer receives the seat belt extender and calls customer in to check fit of the part.
5.
If the seat belt extender fit is OK, dealer completes the customer information label on the part, explains usage of



FRONT SEAT EXTENDER APPLICATION TABLE
NOTE:
The front lap belt for all '90 Corolla models and the '90 Tercel is the ALR type. Make sure the ALR is locked when


REAR SEAT EXTENDER APPLICATION TABLE
Note:
The extender must not be used for the center rear seat belt on any model.

OWNER INSTRUCTION:
(I) By anyone other than for whom it was provided (name recorded on seat belt extender).

(II) In any vehicle and/or seat position other than the one for which it is provided.
2.
4.
OWNER'S MANUAL TEXT:
SEAT BELT EXTENDER
If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender~is availabl
CAUTION:
Never use the seat belt extender if you can fasten the seat belt without it.
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another pe


SEAT BELT EXTENDER WORKSHEET
> Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Seat Belts - Extension Availability
Seat Belts - Extension Availability
BODYBO030-97
October 24, 1997
Title: SEAT BELT EXTENDERS
Models: All '94 through '98 model years
Introduction
Toyota customers who find it necessary to increase the length of their seat belts may obtain Seat Belt Extenders at no c
^ The extender is available in 6 inch, 9 inch, 12 inch, 15 inch and 18 inch lengths.
^ The extender is available only in black.
^ Owners are informed of the seat belt extender availability through the Toyota Owner's Manual included in each veh
The customer (individual requiring the extender) must visit a Toyota dealership to have the required measurements mad
The dealership service department should complete the affixed Seat Belt Extender Label and review the 'owner instruct
To assure utmost owner satisfaction, it is recommended that a dealership designate one person to coordinate all activitie
From past sales history, it is recommended that dealerships do not stock Seat belt extenders due to low demand and the
This bulletin contains the following information:

Procedure and Flow Chart Application Chart and Notes Part Number Information Owner Instructions
> Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Seat Belts - Extension Availability > Page 3715

Seat Belt Extender Worksheet
Affected Vehicles
All Toyota models, 1994 through 1998 model years.

Parts information
Procedure

1. Owner requests a seat belt extender from dealer.
2. Dealer verifies the need for a seat belt extender and obtains a current copy of this TSB and copies the worksheet.
3.
Dealer measures the customer and completes the worksheet. Dealer determines the correct part number and place
4. Dealer receives seat belt extender and calls the customer in to check fit of the part.
5.
If the seat belt extender fit is good, dealership personnel completes the customer information label on the part, ex
Sample Seat Belt Extender Label



Front Seat Belt Extender ApplicationsRear Seat Belt Extender Applications
Owner Instructions

The seat belt extender must not be used:
a. By anyone other than for whom it was provided (name recorded on seat belt extender).
b. In any vehicle and/or seat position other than the one for which it was provided.
c. When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure the r
If your seat belt cannot be fastened securely because it is not long enough, a personalized seat belt extender is available
CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result In less eff
^ Never use the seat belt extender if you can COMFORTABLY fasten the seat belt without it.
^
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another perso
Seat Belts - Extender Availability
BODYB0020-98
July 3, 1998
Title:1999 TOYOTA SEAT BELT EXTENDERS
Models:All '95 through '99 model years
Affected Vehicles
^ All Toyota models, 1995 through 1999 model years.


Front Seat Belt Extender Applications

Rear Seat Belt Extender Applications

Parts Information
Introduction



Procedure and Flow Chart Application Chart and NotesPart Number InformationOwner InstructionsSeat Belt Extender
Procedure
3.
5.
If the seat belt extender fit is good dealership personnel completes the customer information label on the part exp
Owners Instructions
Failure to follow the recommendations indicated below could result in reduced effectiveness of the seat belt restraint sy

C. When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure th

CAUTION:
When using the seat belt extender, observe the following. Failure to follow these instructions could result in reduce
^ The seat belt extender must never be used with any child safety seats.
^
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another p
BO00996Technical Service Bulletin #
Seat Belts - Extender Availability

Ref.: BODY
No.: B0009-96
Date: OCTOBER 25, 1996
Model: ALL MODELS
Title: SEATBELT EXTENDER FOR 1993 THROUGH 1997 MODELS
^ The extender is available in black only, in 6, 9, 12, 15 and 18 inch lengths.
^ Owner's are informed of the seat belt extender availability through the Toyota Owner's Manual included in each veh

The customer (individual requiring the extender) must visit a Toyota Dealership to have the required measurements ma

Included in this bulletin is the information covering the 1993 through 1997 model years:
Contents
Procedure & Flow Chart



Application Charts & Notes
Part Number Information
Owner Instruction Sheet
Statement from Owners Manual

dealership should give a copy of the completed worksheet to the customer and keep the original in the customer's file.
From past sales history, it is recommended that dealerships do not stock seat belt extenders due to low demand and the
SAMPLE SEAT BELT LABEL:


Procedure
2. Dealer verifies the need for a seat belt extender and obtains a current copy of TSB and copies the worksheet.
3.
4. Dealer receives the seat belt extender and calls the customer in to check fit of the part.
5. If the seat belt extender fit is OK, dealership personnel completes the customer information label on the part, exp

the customer a copy of the completed worksheet.
NOTES:
*1.
If dimension "L" is under 24 inches the extender must not be used due to its design and construction. This app
^ '93 & '94 Tercel
^ '93, '94, '95 Paseo
^ '93 Corolla 4WD Wagon
*2.
This seat belt was supplied by TOKAI RIKA. Make sure that the identification mark on the back side if the se
*3. This seat belt was supplied by QSS. Make sure that the identification mark on the back side if the seat belt bu
*4
Extenders must not be used for center front seat belt positions for Avalon, Tacoma, Compact Pickup and T1O

Owner Instruction
(a) By anyone other than for whom it was provided (name recorded on seat belt extender).
(b) In any vehicle and/or seat position other than the one for which it is provided.
2.
4.
Owner's Manual Text
Seat belt extender
CAUTION:
^ Never use the seat belt extender if you can fasten the seat belt without it.
^
Remember that the extender provided for you may not be safe when used on a different vehicle, or for another perso

Seat Belt Extension: Technical Service BulletinsSeat Belts - Extender Availability.
BODYBO012-98
May 8, 1998
Title:SEAT BELT EXTENDERS
Models:All '94 through '98 model year
TSB Update Notice:

The information contained in this TSB updates BO03097 dated October 24, 1997.
Introduction
Procedure and Flow Chart Application Chart and NotesPart Number Information Owner InstructionsSeat Belt Extende
Affected Vehicles
^ All Toyota models, 1994 through 1998 model years.

Procedure

3.
5.
If the seat belt extender fit is good, dealership personnel completes the customer information label on the part, ex


Front Seat Belt Extender Applications

Rear Seat Belt Extenders Applications

Parts Information
Owner Instructions
c.
When the seat belt extender is provided for rear seat positions (with automatic locking retractor), make sure
CAUTION:
^ Remember that the extender provided for you may not be safe when used on a different vehicle, or for another p

position than the one originally intended for.

> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions
Seat Belt Reminder Buzzer: Diagram Information and Instructions
Ground Points
Ground Points
System Outline
TERMINAL 3(1G-9)Current always flows to of the integration relay through the dome fuse.
1. SEAT BELT WARNING SYSTEM

ON GAUGE TERMINAL 9
TERMINAL 2(1E-2) GAUGE
4-8 seconds TERMINAL 2(1E-2)
--> TERMINAL7(1E-7) --> GROUND OFF
TERMINAL 5(1E-5) TERMINAL 3(1G-9) TERMINAL 7(1E-7) --> GROUND
4-8 seconds ON
TERMINAL 5(1E-5) TERMINAL 3(1G-9)
--> TERMINAL 7(1E-7) -->GROUND When the ignition SW is turned , current flows from the fuse to the of
2. UNLOCK WARNING SYSTEM
ON OFF ON
TERMINALS 4(1E-4) 8(1I-9)
TERMINAL 3(1G-9) --> TERMINAL 7(1E-7) --> GROUNDWith the ignition key inserted in the key cylinde
Parts Location
> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 3749

Parts Location


Position Of Parts In Body (Part 1 Of 2) (Fig 32)

Service Hints
U 1 UNLOCK WARNING SW
1-2: Closed with ignition key in cylinder
B 7 BUCKLE SW LH
1-2: Closed with driver's seat belt in use
INTEGRATION RELAY

9(1E-9)-Ground: 12 Volts ONApprox. with ignition SW at position
5(1E-5)-Ground: Continuity with driver's seat belt in use
4(1E-4)-Ground: Continuity with ignition key in cylinder
7(1E-7)-Ground: Always continuity
3(1G-9)-Ground: 12 VoltsAlways Approx.
8(1I-9)-Ground: Continuity with front LH door open





J/B No.4 Inner Circuit (Fig 26)
Seat Belt Reminder Buzzer: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Unlock And Seat Belt Warning-Connectors

Unlock And Seat Belt Warning
> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Diagrams > Page 3770
Seat Belt Reminder Buzzer: Description and Operation


ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions
Seat Belt Reminder Lamp: Diagram Information and Instructions

> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3775




Parts Location
Parts Location




Service Hints
B 7 BUCKLE SW LH
INTEGRATION RELAY

System Outline

ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
Ground Points
Ground Points
Seat Belt Reminder Lamp: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON

> Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 3796
Seat Belt Reminder Lamp: Description and Operation


ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - OCS System Initialization
DATE: MARCH 2010
NOTE:
> Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Audio - AM Static Noise On Vehicles with Power Antennas
Antenna: Technical Service BulletinsAudio - AM Static Noise On Vehicles with Power Antennas
Ref.: AUDIO
No.: AU002-96
Model: ALL MODELS
AM STATIC NOISE ON VEHICLES WITH POWER ANTENNAS
Vehicles with power antennas may exhibit audible electrical noise on weak AM stations when various electrical access
Poor antenna grounding can cause this condition.
To eliminate or reduce the intensity of the noise, use the following repair procedure:
REPAIR PROCEDURE;
1.
Tune the radio to a strong, static-free AM station and slowly move the tip of the antenna mast forward and back a
NOTE:
Do not touch the antenna mast with your bare hands. Use a glove or nonmetallic object to move the antenna. (If you
2. Remove the antenna mast and inspect the base of the mast for corrosion and damage (fig 2). Clean with 1500 grit
> Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Audio - AM Static Noise On Vehicles with Power Antennas >
Page 3807

3. Remove the antenna assembly and inspect the inner fender around the antenna hole for corrosion (fig 3). Clean w
4. Remove the antenna spacer grommet at the top of the antenna assembly and inspect for corrosion (fig 4). Clean w
5.
Reinstall the antenna assembly. Be sure to install the external antenna nut (escutcheon) first. Then install the nut
6. Check to make sure that the teeth on the antenna spacer grommet make good contact with the inner fender well (f
> Accessories and Optional Equipment > Antenna > Component Information > Technical Service Bulletins > Audio - AM Static Noise On Vehicles with Power Antennas >
Page 3808

7. Inspect the antenna cable connection and clean as necessary. Reconnect the antenna cable, the wire harness and th
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry
Guide
Keyless Entry Transmitter: Technical Service BulletinsKeyless Entry - Remote Transmitter Programming Guid
ELECTRICALEL010-07REVISED
Title:WIRELESS TRANSMITTER &PROGRAMMING GUIDE
Models:'90 - '08 Applicable Toyota
November 9, 2007
^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart.
TSB UPDATE NOTICE:

The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and sho
Introduction
Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota
Applicable Vehicles
^ 1990 - 2008 model year applicable Toyota vehicles.
System Identification
The Application Chart contains all of the necessary information to correctly identify the type of system installed, and w
Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in w
^
Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade veh
^
Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, ref
^
Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "con
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins
> Keyless Entry - Remote Transmitter Programming Guide > Page 3815




Application Chart



Wireless Transmitter Identification
> Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry
Guide > Page 3822
Keyless Entry Transmitter: Technical Service BulletinsKeyless Entry - Transmitter Programming & Identificat
December 20, 2002
Title:WIRELESS TRANSMITTER & PROGRAMMING GUIDE
Models:All Applicable


^
February 28, 2003: In Wireless Transmitter Identification section Figures 5, 9, 10,1 2, and 13 as shown are upda
^ January 17, 2003: 2003 model year added to Solara in the Application Chart.
^ The information contained in this TSB supercedes TSB EL010-01, dated October 26, 2001. The previous TSB,
Introduction

Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory
All applicable
Applicable Toyota vehicles.
Vehicles^



The table contains all of the necessary information to correctly identify the type of system installed, and where to go to
NOTE:
Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in
^
Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade v
^
Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located,
^
Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "c
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - AM Static Noise On Vehicles w
Radio/Stereo: Technical Service BulletinsAudio - AM Static Noise On Vehicles with Power Antennas
Ref.: AUDIO
No.: AU002-96
Model: ALL MODELS
AM STATIC NOISE ON VEHICLES WITH POWER ANTENNAS
Vehicles with power antennas may exhibit audible electrical noise on weak AM stations when various electrical access
Poor antenna grounding can cause this condition.
To eliminate or reduce the intensity of the noise, use the following repair procedure:
REPAIR PROCEDURE;
1.
Tune the radio to a strong, static-free AM station and slowly move the tip of the antenna mast forward and back a
NOTE:
Do not touch the antenna mast with your bare hands. Use a glove or nonmetallic object to move the antenna. (If you
2. Remove the antenna mast and inspect the base of the mast for corrosion and damage (fig 2). Clean with 1500 grit
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - AM Static Noise
On Vehicles with Power Antennas > Page 3833

3. Remove the antenna assembly and inspect the inner fender around the antenna hole for corrosion (fig 3). Clean w
4. Remove the antenna spacer grommet at the top of the antenna assembly and inspect for corrosion (fig 4). Clean w
5.
Reinstall the antenna assembly. Be sure to install the external antenna nut (escutcheon) first. Then install the nut
6. Check to make sure that the teeth on the antenna spacer grommet make good contact with the inner fender well (f
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Technical Service Bulletins > Audio - AM Static Noise
On Vehicles with Power Antennas > Page 3834

7. Inspect the antenna cable connection and clean as necessary. Reconnect the antenna cable, the wire harness and th
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions
Radio/Stereo: Diagram Information and Instructions
Connector Joining Wire Harness and Wire Harness
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions >
Page 3837

Ground Points
Ground Points
Page 3838

Parts Location
Parts Location
Page 3839

Page 3840

Page 3841

Service Hints
R 2-A RADIO AND PLAYER
12 Volts 12 Volts ON ACC

A-4-Ground: Always approx. A-3-Ground: Approx. with ignition SW at or positionA-7-Ground: Always contin
Page 3842

Page 3843

Page 3844

Page 3845

> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Component Information > Diagrams > Diagram Information and Instructions > Page 3846
Radio/Stereo: Diagnostic Aids
Page 3847

Page 3848

Page 3849

Special Tool

Page 3850

HINT:
"Case 1"
"Case 2"

: Connector Body
Page 3851

"Case 1"
HINT:
"Case 2"
Page 3852

Terminal Retainer
Locking Lug

HINT:
Page 3853


Page 3854

CAUTION:
Voltage Check
ON
Page 3855

Voltage Check
ON
Radio And Player-connectors

Radio And Player
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions
Tape Player: Diagram Information and Instructions
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions >
Page 3862

Ground Points
Ground Points
Page 3863


Page 3864

Page 3865

Page 3866

Parts Location
Parts Location
Page 3867

Page 3868

Page 3869

Service Hints
R 2-A RADIO AND PLAYER
12 Volts 12 Volts ON ACC

A-4-Ground: Always approx. A-3-Ground: Approx. with ignition SW at or positionA-7-Ground: Always contin
> Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Diagrams > Diagram Information and Instructions > Page 3870
Tape Player: Diagnostic Aids
Page 3871

Page 3872

Page 3873

Special Tool

Page 3874

HINT:
"Case 1"
"Case 2"

: Connector Body
Page 3875

"Case 1"
HINT:
"Case 2"
Page 3876

Terminal Retainer
Locking Lug

HINT:
Page 3877


Page 3878

CAUTION:
Voltage Check
ON
Page 3879

Voltage Check
ON
Radio And Player-connectors

Radio And Player
> Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide.
Towing Information: Technical Service BulletinsVehicle - Towing Guide.
BULLETIN NUMBER:AX001-00
DATE:March 17, 2000
TITLE:TOYOTA "DINGHY" TOWING GUIDE
MODELS:All Models
INTRODUCTIONThe chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four w
CAUTION:
Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Mot
WARRANTY INFORMATION
APPLICABLE VEHICLES
> Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide. >
Page 3887

NOTE:
After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before ope
NOTE:
must
Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long
> Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Technical Service Bulletins > Vehicle - Towing Guide. > Page 3888
Towing Information: Technical Service BulletinsVehicle - Towing Guide
ACCESSORIESAX004-99
March 19, 1999
Title:TOYOTA "DINGHY" TOWING GUIDE
Models:
All Models
Introduction: The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on th
CAUTION:
Dinghy towing 6 vehicle behind a Motorhome requires special towing equipment and accessories. Please see your M
Affected Vehicles
- All Models
Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The tran
> Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing
Front Bumper Cover / Fascia: Technical Service BulletinsBody - Plastic Bumper Refinishing
TITLE: PLASTIC BUMPER REFINISHING
SECTION: REFINISH
BULLETIN # 170
MODELS: ALL TOYOTA LEXUS and SCION
DATE: OCTOBER 2008
When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refi
Background:
Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures ou
Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC
Cleaning and Preparation:
^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse we
Cleaning and Preparation, Continued-
^
Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or wate
^
Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with
^
Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuf
^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropy
^ Apply anti-static measures.
^ Apply adhesion promoter per paint manufacturer7s recommendations.
^ Apply primer and topcoats per paint manufacturer7s recommendations.
Note:
Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion,
Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic
> Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing >
Page 3896

promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropyle
> Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing > Page 3897
Front Bumper Cover / Fascia: Technical Service BulletinsPaint - Refinishing Bumper Cover
PAINT PA003-02REVISED
June 4, 2002
TitleREFINISHING REPLACEMENT BUMPER COVERS
ModelsAll '83 - '05 Models
TSB REVISION NOTICE:^ February 14, 2005: Applicable Vehicles now includes 2004 - 2005 model years. Previous
IntroductionIn cases where a bumper cover is being replaced a special preparation process is necessary to assure the ref
Applicable Vehicles^ All 1983 - 2005 model year Toyota vehicles.
Note:Please visit www.3m.comlautomotive to find the nearest store that sells 3M automotive products.
Refinishing Procedure
1. Mix a solution of mild soap (car wash soap with no wax additives) and clean water.
Note:
Carefully follow mixing instructions on the soap container. Too much soap or too much water may cause surface
> Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing >
Page 3898

2. Scrub the bumper covers with the soap and water solution, making sure all difficult-to-reach areas are thoroughly
3. Rinse the entire bumper cover with clean deionized water, making sure all difficult-to-reach areas are thoroughly
4. Dry the surface with a clean towel before water dries on the surface. Clean, dry compressed air from an oil-less co
drying with a towel.
5. Degrease the surface with a wax, grease, and silicone remover.
Note:
Lacquer thinner or brake cleaner will NOT remove silicone. You MUST use a wax, grease, and silicone remover
6. Apply a generous amount of sanding paste with a gray 3M ScotchBrite pad. Only a gray pad should be used durin
entire bumper cover surface. Be sure all difficult-to-reach areas are thoroughly sanded.
7. Clean the entire bumper cover with car wash soap and water. Be sure all difficult-to-reach areas are thoroughly cl
8. Rinse the entire bumper with clean deionized water. Be sure all difficult-to-reach areas are thoroughly rinsed.
9. Degrease the surface with an anti-static plastic parts cleaner and a white body shop towel or paper towel.
Note: Never use a red shop towel to wipe the surface (contains silicone).
10. Assure the bumper is firmly held in place to a steady fixture.
11. Apply a plastic parts adhesion promoter to the surface, according to the manufacturer's recommendations.
12. Apply plastic parts primer to the surface, according to the paint manufacturer's recommendations.
13. Since bumpers are made of flexible plastic urethane material, use a two-part urethane finish paint system with pla
bumper and cladding repairs. Apply the appropriate top coat to the surface, according to the paint manufacturer's
14. If heat is applied to cure the paint, assure the surface temperature does not exceed 80C (176F.)
For additional information concerning the refinish process for plastic bumpers/cladding, please contact your respective
> Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Bumper Component Repair
Front Bumper Reinforcement: Technical Service BulletinsBody - Bumper Component Repair
TITLE: BUMPER COMPONENT REPAIR
SECTION: EXTERIOR BULLETIN # 172
DATE: MARCH 2009
While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinf
For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Col
> Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing
Rear Bumper Cover / Fascia: Technical Service BulletinsBody - Plastic Bumper Refinishing
TITLE: PLASTIC BUMPER REFINISHING
SECTION: REFINISH
BULLETIN # 170
DATE: OCTOBER 2008
When it is necessary to replace a damaged plastic bumper, proper consideration should be given to preparation and refi
Background:
Toyota bumper covers are manufactured using several types of plastic however, cleaning and preparation procedures ou
Soap-base mold release agent replaced the wax-base type beginning in 1995 to reduce volatile organic compound (VOC
Cleaning and Preparation:
^ Wash new part thoroughly inside and out with a hot water and ph neutral wax-free carwash soap solution. Rinse we
Cleaning and Preparation, Continued-
^
Clean exterior surface and all edges thoroughly with paint manufacturer recommended plastic parts cleaner or wate
^
Scuff exterior surface and all edges with a medium to fine scuff pad (as recommended by paint manufacturer), with
^
Examine the bumper closely, especially hard to reach areas. Re-scuff any areas that do not appear to have been scuf
^ Make final surface inspection and clean with paint manufacturer recommended cleaner or a 1-1 mixture of isopropy
^ Apply anti-static measures.
^ Apply adhesion promoter per paint manufacturer7s recommendations.
^ Apply primer and topcoats per paint manufacturer7s recommendations.
Note:
Toyota recommends the use of adhesion promoter and elastifier for all OE raw plastic bumpers to ensure adhesion,
Toyota, Lexus and Scion bumpers are primarily made from TSOP (Toyota Super Olefin Polymer). This type of plastic
> Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing > Page
3908

promoters. However, the application of adhesion promoters on earlier model bumpers made from PP/TPU (Polypropyle
> Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing > Page 3909
Rear Bumper Cover / Fascia: Technical Service BulletinsPaint - Refinishing Bumper Cover
June 4, 2002
Note:
> Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - Plastic Bumper Refinishing > Page
3910

Note:
> Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Bumper Component Repair
Rear Bumper Reinforcement: Technical Service BulletinsBody - Bumper Component Repair
TITLE: BUMPER COMPONENT REPAIR
DATE: MARCH 2009
While it may seem cost effective to repair damaged bumper components specifically impact energy absorbers and reinf
For more information on collision damage repair topics please refer to Collision Repair Information Bulletin # 161 Col
> Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Technical Service Bulletins > Fuel Door - Improved Operation In Cold Climate
Fuel Door: Technical Service BulletinsFuel Door - Improved Operation In Cold Climate
BODYBO002-97
February 14, 1997
Title: FUEL DOOR OPERATION IN COLD CLIMATE
Models: '96 Corolla
Introduction
To improve cold climate fuel door operation on North American produced Corolla models, a production change has be
^ 1996 Corollas starting with VINs: 1NX* * * * *TZ498593
2T1BA02EXTC1551462T1BB02E4TC174692
NOTE:
Japan built Corollas are not affected.
Field-Fix Procedures
Trim approximately 1 mm from the tip of the rubber door stop studs, which are integral to the fuel door inlet gasket.
NOTE:
If rubber door stop studs are trimmed more than 2 mm, a door rattle could occur.
> Body and Frame > Exterior Moulding / Trim > System Information > Technical Service Bulletins > Body/Interior - Trim Removal & Installation
Exterior Moulding / Trim: Technical Service BulletinsBody/Interior - Trim Removal & Installation
TITLE: TRIM REMOVAL & INSTALLATION
SECTION: GENERAL BULLETIN #167
DATE: JULY 2OO8
During collision repair and refinish operations it is often necessary to remove interior and exterior trim. Instructions an
This information can enhance productivity and reduce damage to reusable trim and fasteners. It is important to remove
The illustration is provided as an example of available information shown.

> Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Carpet Cleaning Precautions
Carpet: Technical Service BulletinsInterior - Carpet Cleaning Precautions

Ref.: BODY
No.: BO011-96
Date: DECEMBER 13, 1996
Model: ALL MODELS
Title: CARPET CLEANING PROCEDURES
Electrical components, wire harnesses1 and connectors in the cabin and trunk areas are not waterproof and therefore, ar
When cleaning the carpet in the vehicle, use dedicated carpet cleaning equipment such as the carpet and upholstery clea
NOTE:
Even with dedicated carpet cleaning equipment, you must be careful not to soak electrical components located unde
> Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations

> Body and Frame > Locks > Door Locks > Door Lock Relay > Component Information > Locations > Page 3938



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Programming Guide
Keyless Entry Transmitter: Technical Service BulletinsKeyless Entry - Remote Transmitter Programming Guid
Title:WIRELESS TRANSMITTER &PROGRAMMING GUIDE
Models:'90 - '08 Applicable Toyota
November 9, 2007
^ November 10, 2007: A TSB reference has been updated in the Programming column of the Application Chart.
TSB UPDATE NOTICE:

The information contained in this TSB supersedes TSB No. EL008-02. TSB No. EL008-02 is now obsolete and sho
Introduction
Difficulties during Remote Keyless Entry (RKE) Transmitter Programming can arise due to confusion between Toyota
Applicable Vehicles
^ 1990 - 2008 model year applicable Toyota vehicles.
The Application Chart contains all of the necessary information to correctly identify the type of system installed, and w
Should a vehicle having both VIP and Factory systems available (as identified in the Application Chart) be brought in w
^
Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade veh
^
Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or on
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located, ref
^
Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "con
> Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter
Programming Guide > Page 3948




Application Chart



Wireless Transmitter Identification
> Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Technical Service Bulletins > Keyless Entry - Remote Transmitter Programming Guide
Keyless Entry Transmitter: Technical Service BulletinsKeyless Entry - Transmitter Programming & Identificat
December 20, 2002
Title:WIRELESS TRANSMITTER & PROGRAMMING GUIDE
Models:All Applicable


^
February 28, 2003: In Wireless Transmitter Identification section Figures 5, 9, 10,1 2, and 13 as shown are upda
^ January 17, 2003: 2003 model year added to Solara in the Application Chart.
^ The information contained in this TSB supercedes TSB EL010-01, dated October 26, 2001. The previous TSB,
Introduction

Difficulties during Remote Keyless Entry Transmitter Programming can arise due to confusion between Toyota Factory
All applicable
Applicable Toyota vehicles.
Vehicles^



The table contains all of the necessary information to correctly identify the type of system installed, and where to go to
NOTE:
Should a vehicle having both VIP and Factory systems available (as identified in the following table) be brought in
^
Look at the Trim Level of the vehicle. Higher-grade vehicles will tend to have O.E. systems, while entry-grade v
^
Look for a "Status Monitor" with a glass breakage sensor and an LED externally installed into the dashboard or
^ Locate the ECU (refer to the applicable vehicle VIP Manual installation instructions for location). Once located,
^
Attempt to perform the factory wireless programming procedure to get a response from the vehicle. Select the "c
> Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions
Mirrors: Diagram Information and Instructions
Service Hints
R 5 REMOTE CONTROL MIRROR SW
12 Volts ACC ON
UP LEFT
8-Ground: Approx. Continuity
with ignition with
SW atoperation SW at or position
or position7-3:
8-7: DOWN RIGHTContinuity with operation SW at or position
3-Ground: Always continuity
Parts Location
Parts Location
> Body and Frame > Mirrors > Component Information > Diagrams > Diagram Information and Instructions > Page 3965








Ground Points
Ground Points

Mirrors: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Remote Control Mirror-Connectors

Remote Control Mirror
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Refinishing Information
Paint: Technical Service BulletinsPaint - Refinishing Information
TITLE: TOPCOAT SAND & POLISH
SECTION: REFINISH BULLETIN # 173
MODELS: ALL TOYOTA LEXUS AND SCION
DATE: APRIL 2009
Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color glo
Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blen
Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint F
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB173 > Apr > 09 > Paint - Refinish
Paint: Technical Service BulletinsPaint - Refinishing Information
TITLE: TOPCOAT SAND & POLISH
SECTION: REFINISH BULLETIN # 173
MODELS: ALL TOYOTA LEXUS AND SCION
DATE: APRIL 2009
Customers have high expectations for automotive paint finish appearance and expect repairs to match factory color glo
Toyota recognizes the reality of paint finish application in the shop environment. In addition to color matching and blen
Topcoat sand and polish is one of many paint finish repair techniques covered in Toyota T101 and Lexus L101 Paint F
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB165 > Mar > 09 > Body - Acid R
Paint: Technical Service BulletinsBody - Acid Rain Paint Damage Prevention/Repair

TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR
SECTION: EXTERIOR
BULLETIN # 165
DATE: MARCH 2008
Condition & Cause
'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often re
Prevention of Finish Damage
While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not care
Dealers should refer to the Toyota Warranty Policy and Procedures Manual,
Policy No.2.3 for information on Storage and Protection of New Vehicles.
Detailed information is also provided on proper finish care in the Owner's Manual of all models.
In brief, following washing and wax application recommendations should keep paint looking good.
Inspection & Repair
Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, a
University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed informa
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB146 > Sep > 06 > Body - Paintles
Paint: Technical Service BulletinsBody - Paintless Dent Repair Information

TITLE: PAINTLESS DENT REPAIR
MODELS: TOYOTA, SCION AND LEXUS
DATE: SEPTEMBER 2006
Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, S
PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be
Repair Precautions
^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is poss
^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses,
^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical
^
PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mecha
General Repair Guidelines
^
The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power
Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. P
PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION RE
Important:
The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutt
^
Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process
^ Window guard protectors must be used to protect window glass during PDR operations.
Specific Repair Guidelines

^
Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrit
Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings cau
^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larg
^ Creases that are up to 4 long may be considered for removal.
Note:
Sharp creases cannot be removed using PDR.
^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be con
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB146 > Sep > 06 >
Body - Paintless Dent Repair Information > Page 4003

be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken pa
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA003R-02 > Feb > 05 > Paint - Refin
Paint: Technical Service BulletinsPaint - Refinishing Bumper Cover
June 4, 2002
Note:
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA003R-02 > Feb > 05
> Paint - Refinishing Bumper Cover > Page 4008

Note:
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA005R-04 > Dec > 04 > Paint - Iron R
Paint: Technical Service BulletinsPaint - Iron Rust Contamination Repair
November 16, 2004
TitleIRON PARTICLE RUST CONTAMINATION REPAIR
Models'94 - Current Toyota & '04 - Current Scion
TSB REVISION NOTICE:^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Mag
IntroductionThe purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles tha
Applicable Vehicles^ 1994 - Current model year Toyota vehicles.^ 2004 - Current model year Scion vehicles.
ConditionDuring rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to
InspectionThis type of contamination can be identified by the presence of small red or brown particles on the paint surf
Caution:
Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to re
Required Tools & Materials

RepairWashing the affected paint surfaces with Auto Magic Special Cleaner Concentrate is the recommended method
General Precautions
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA005R-04 > Dec > 04
> Paint - Iron Rust Contamination Repair > Page 4013

Warning: Auto Magic Special Cleaner Concentrate is a corrosive material. Appropriate personal protection eq
Caution:
Consult local or state regulations regarding the handling, use, and disposal of Auto Magic Special Cleaner Concentr
Under no circumstances should contamination removal be performed in direct sunlight or contamination removal sol
Repair Procedure
1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rins
water.
2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any o
cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface.
3. Thoroughly rinse vehicle with fresh water.
4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the
to achieve complete removal.
5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish.
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB71 > Jul > 96 > Paint - Paint Proc
Paint: Technical Service BulletinsPaint - Paint Procedures
COLLISION REPAIR INFORMATIONCRIB71
TITLE: PAINT GUIDE AND REFINISH PROCEDURES
SECTION: REFINISH BULLETIN #71
MODELS: ALL
DATE: JULY 1996
The following guide describes paint types as they relate to paint code and specific model type, along with recommende
^ Locate the paint code on the vehicle.
^ Reference the paint guide for paint code, model and paint type.
^ Verify paint type on page 4.
^ Reference the recommended refinish procedure according to the paint type as listed on pages 5-9.
The actual number of paint coats may vary depending upon pigment, metallic, pearl mica flakes and application techniq
1996 TOYOTA PAINT CODES, MODEL AND PAINT TYPES

> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB71 > Jul > 96 >
Paint - Paint Procedures > Page 4018


TWO-TONE COMBINATIONS

REFINISH PROCESS FOR PAINT TYPE #1 (Single Stage Paint)

REFINISH PROCESS FOR PAINT TYPE #2A (Two Stage Paint Without Color Sealer)

REFINISH PROCESS FOR PAINT TYPE #2B (Two Stage Paint With Color Sealer)

REFINISH PROCESS FOR PAINT TYPE #3 (Two Stage Paint With Tinted Clear Coat)

REFINISH PROCESS FOR PAINT TYPE #4 (Three Stage Paint)

> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB70 > Apr > 96 > Paint - Paint Cod
Paint: Technical Service BulletinsPaint - Paint Codes
COLLISION REPAIR INFORMATIONCRIB70
TITLE: 1996 PAINT AND REFINISH FORMULA CODES
SECTION: REFINISH BULLETIN #70
MODELS: ALL
DATE: APRIL 1996
Attached for your reference is a list of all 1996 Toyota paint codes and the refinish paint codes for the following refinis
BASF; DuPont, PPG, Sherwin-Williams, Sikkens, Spies-Hecker and ICI AutoCol or.
NOTE: The paint code is on the certification label which can be located on the driver's side door jamb or the lower sec
NOTE: Please contact your local paint representative for the actual paint mixing formulas or if you need help in color
1996 TOYOTA PAINT CODES AND COLOR NAMES

> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > CRIB70 > Apr > 96 >
Paint - Paint Codes > Page 4030



TWO-TONE COMBINATIONS
TRUCK BUMPER COLORS

> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA00196 > Mar > 96 > Paint - Codes &
Paint: Technical Service BulletinsPaint - Codes & Cross References

REF.: PAINT
NO.: PA001-96
MARCH 22, 1996
MODEL: ALL MODELS
1996 PAINT AND REFINISH FORMULA CODES
Included for your reference is a list of all 1996 OEM paint codes and refinish paint codes for the following refinish pain
BASF, DuPont, PPG, Sherwin Williams, Sikkens, Spies-Hecker and ICI
NOTE:
The body color code is located on the certification label which is located in the left front door area.
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > PA00196 > Mar > 96 >
Paint - Codes & Cross References > Page 4037



1996 TOYOTA PAINT CODES AND COLOR NAMES



1996 TOYOTA PAINT APPLICATIONS AND PAINT TYPES
> Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Technical Service Bulletins for Paint: > Page 4043
Paint: Technical Service BulletinsBody - Acid Rain Paint Damage Prevention/Repair

TITLE: ACID RAIN PAINT FINISH DAMAGE - PREVENTION & REPAIR
SECTION: EXTERIOR
BULLETIN # 165
DATE: MARCH 2008
Condition & Cause
'Acid Rain' is the result of rainwater and other forms of airborne moisture mixing with atmospheric impurities, often re
Prevention of Finish Damage
While Toyota, Lexus, and Scion paint finishes are engineered to look great and provide long-term durability, if not care
Dealers should refer to the Toyota Warranty Policy and Procedures Manual,
Policy No.2.3 for information on Storage and Protection of New Vehicles.
Detailed information is also provided on proper finish care in the Owner's Manual of all models.
In brief, following washing and wax application recommendations should keep paint looking good.
Inspection & Repair
Acid rain damage can usually be identified visually and by touch. Stains look similar to hard-water spotting however, a
University of Toyota e-learning course E257- Vehicle Delivery Quality- Paint Finish Repair, provides detailed informa
Paint: Technical Service BulletinsBody - Paintless Dent Repair Information

TITLE: PAINTLESS DENT REPAIR
MODELS: TOYOTA, SCION AND LEXUS
DATE: SEPTEMBER 2006
Toyota has developed the following guidelines for the use of "Paintless Dent Repair (PDR) procedures on all Toyota, S
PDR is used to reduce the cost of repairing minor dents and to avoid color match and refinish issues that may arise. Be
Repair Precautions
^ Always refer to the specific vehicle schematic (available from your PDR provider) for locations where PDR is poss
^ Pay close attention to the locations of accessories and subassemblies that may utilize wire harnesses or drain hoses,
^ PDR is often complicated by panel contour, placement of reinforcements, and location of electrical and mechanical
^
PDR Technicians should be aware of and take the necessary precautions to prevent damage to electrical and mecha
General Repair Guidelines
^
The PDR process should only be considered when the exterior paint surface is not broken or cracked. A 30X power
Pushing and prying on the back side of body panels can disrupt the factory rust and corrosion protective coatings. P
PLEASE ROUTE THIS BULLETIN TO YOUR COLLISION REPAIR CENTER MANAGER AND COLLISION RE
Important:
The PDR process uses special tools to access otherwise inaccessible areas. Drilling of holes, prying away or cutt
^
Using blocks or wedges between window moldings and door glass (for tool access) is also prohibited. This process
^ Window guard protectors must be used to protect window glass during PDR operations.
Specific Repair Guidelines

^
Panels with multiple dents, including hail damage, may be considered for PDR as long as the original panel integrit
Prying, pushing, or pulling on body panels may cause stretching beyond the flexible limits of the paint coatings cau
^ Round/oval dents may be removed if they are 2 inches or more away from panel edges or body lines and are no larg
^ Creases that are up to 4 long may be considered for removal.
Note:
Sharp creases cannot be removed using PDR.
^ Dents or protrusions, of up to 6mm, from the reverse side, on hoods, trunks, fenders, and quarter panels may be con

be used during this type of repair due to the higher potential of damaging the paint surface. Remember no broken pa
Paint: Technical Service BulletinsPaint - Iron Rust Contamination Repair
November 16, 2004
TitleIRON PARTICLE RUST CONTAMINATION REPAIR
Models'94 - Current Toyota & '04 - Current Scion
TSB REVISION NOTICE:^ December16, 2004: Text has been revised to more accurately describe cleaner (Auto Mag
IntroductionThe purpose of this bulletin is to provide information regarding the proper procedures to clean vehicles tha
Applicable Vehicles^ 1994 - Current model year Toyota vehicles.^ 2004 - Current model year Scion vehicles.
ConditionDuring rail transportation or extended storage near industrial areas vehicles may occasionally be subjected to
InspectionThis type of contamination can be identified by the presence of small red or brown particles on the paint surf
Caution:
Because of the abrasiveness of these small iron particles, polishing or buffing procedures should not be affempted to re
Required Tools & Materials

RepairWashing the affected paint surfaces with Auto Magic Special Cleaner Concentrate is the recommended method
General Precautions

Warning: Auto Magic Special Cleaner Concentrate is a corrosive material. Appropriate personal protection eq
Caution:
Consult local or state regulations regarding the handling, use, and disposal of Auto Magic Special Cleaner Concentr
Under no circumstances should contamination removal be performed in direct sunlight or contamination removal sol
Repair Procedure
1. Move vehicle out of direct sunlight. Initially rinse with cool water then wash with liquid car wash detergent. Rins
water.
2. Dilute the mixture to a 1:8 ratio for painted surfaces. Use the recommended dilution ratio when applying to any o
cleaner so that it evenly covers the affected area. Use an appropriate mitt or sponge to agitate the surface.
3. Thoroughly rinse vehicle with fresh water.
4. Inspect vehicle carefully both visually and by feel to determine if all iron particles have been removed. Repeat the
to achieve complete removal.
5. Dry vehicle with a soft terry cloth towel and apply a non-abrasive non-silicone glaze to obtain a high-gloss finish.
> Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations

> Body and Frame > Relays and Modules - Body and Frame > Door Lock Relay > Component Information > Locations > Page 4052



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations

> Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Relay > Component Information > Locations > Page 4060



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations

> Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Relay > Component Information > Locations > Page 4070



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Cruise Control > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control: > NHTSA96E00100 > Dec > 95 > Recall 96E00100: Defective Cr
Cruise Control: All Technical Service BulletinsRecall 96E00100: Defective Cruise Control Assemblies
THESE CRUISE CONTROL SYSTEMS FAIL TO HOLD THE SPEED SET BY THE DRIVER AND CAN ACCELE
SYSTEM: FUEL; THROTTLE LINKAGES AND CONTROL EQUIPMENT DESCRIPTION: AFTER MARKET CR
NOTE: OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER IN THESE AFFECTED STA
1900 ROSTRA CRUISE CONTROL
1996 TOYOTA CAMRY1996 TOYOTA CELICA1996 TO

> Cruise Control > System Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control: > NHTSA96E001000 > Dec > 95 > Recall 96E001000: Defective
Cruise Control: All Technical Service BulletinsRecall 96E001000: Defective Cruise Control Systems
> Cruise Control > System Information > Technical Service Bulletins > By Symptom for Cruise Control: > NHTSA96E00100 > Dec > 95 > Recall 96E00100: Defective Cruise Control Asse
Cruise Control: By SymptomRecall 96E00100: Defective Cruise Control Assemblies

> Cruise Control > System Information > Technical Service Bulletins > By Symptom for Cruise Control: > NHTSA96E001000 > Dec > 95 > Recall 96E001000: Defective Cruise Control Sy
Cruise Control: By SymptomRecall 96E001000: Defective Cruise Control Systems
> Cruise Control > System Information > Technical Service Bulletins > Recalls for Cruise Control: > NHTSA96E00100 > Dec > 95 > Recall 96E00100: Defective Cruise Control Assemblie
Cruise Control: RecallsRecall 96E00100: Defective Cruise Control Assemblies

> Cruise Control > System Information > Technical Service Bulletins > Recalls for Cruise Control: > NHTSA96E001000 > Dec > 95 > Recall 96E001000: Defective Cruise Control Systems
Cruise Control: RecallsRecall 96E001000: Defective Cruise Control Systems
> Cruise Control > System Information > Diagrams > Diagram Information and Instructions
Cruise Control: Diagram Information and Instructions
Ground Points
Ground Points
> Cruise Control > System Information > Diagrams > Diagram Information and Instructions > Page 4107





Parts Location
Parts Location



Splice Points
Splice Points

System Outline
STOP TERMINAL 2
ON GAUGE TERMINAL 12
ECU-IG TERMINAL 14
ON ON TERMINAL 15
TERMINAL 19 TERMINAL 14
TERMINAL 13 --> GROUND
GAUGE TERMINAL 12
--> TERMINAL 15 -->TERMINAL 7 --> TERMINAL 13 --> GROUND
Current is applied at all times through fuse to of stop light switch.With the ignition switch turned to , the current flows
1. SET OPERATION
ON
40Kph, 25mph 200Kph, 124mph TERMINAL 19
When the cruise control main switch is turned and the set switch is pushed with the vehicle speed within the set l
2. SET SPEED CONTROL
TERMINAL 20
TERMINAL 12 -->TERMINAL 6 --> TERMINAL 7 --> TERMINAL 11
TERMINAL 11 --> TERMINAL 7

--> TERMINAL 6 --> TERMINAL 12
During cruise
3. COAST CONTROLcontrol driving, the ECU compares the set speed memorized in the ECU with the actual vehicle spe
ON
During the cruise control driving, while the coast switch is , the cruise control actuator returns the throttle cable t
4. ACCEL CONTROL
ON
During cruise control driving, while the Accel switch is turned , the cruise control actuator pulls the throttle cable

5. RESUME CONTROL
40Kph
Unless the vehicle speed falls below the minimum speed limit (Approx. ) after canceling the speed by the cancel
6. MANUAL CANCEL MECHANISM
If any the following operations occurs during cruise control operation, the magnetic clutch of the actuator turns o
^ ON TERMINAL 2 "N"
ON TERMINAL 2Depressing the clutch pedal (cruise control clutch switch ). "signal input to of ECU" (
^ ON TERMINAL 16Depressing the brake pedal (stop light switch ). "signal input to of ECU"
^ ON TERMINAL 18Push the cancel switch (cancel switch ). "signal input to .
7. AUTO CANCEL FUNCTION

A. If any of the following operate conditions occurs during cruise control operation, the set speed is erased, curre
ONstopped and the cruise control is released. (Main switch turns off). When this occurs, the ignition switch m
ON ON
^ Over current to transistor driving motor and/or magnetic clutch.^ When the current continued to flow to
B. If any of the following conditions occur during cruise control operation, the set speed is erased and the cruise c
"ON"magnetic clutch is cut off until the set switch is again.)
40Kph 25mph
16Kph 10mph ON
^ When the vehicle speed fails below the minimum limit, Approx. ()^ When the vehicle speed falls more
C) If any of the following conditions occurs during cruise control operation, the cruise control is released.
TERMINAL 16^ Open circuit for of cruise control ECU.
Cruise Control: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Cruise Control-Connectors
Cruise Control: Electrical Diagrams
Service Hints
C 1 CRUISE CONTROL ACTUATOR
1-3: 2 K OhmsApprox.
C14 CRUISE CONTROL SW [COMB. SW]

15-20: ONContinuity with main SW
17-20: 418 Ohms ON
68 Ohms ON
198 Ohms ONApprox. with cancel SW Approx. with Resume/Accel SW Approx. with Set/C
C15 CRUISE CONTROL ECU
14-Ground: 12 Volts ONApprox. with ignition SW at position
15-Ground: 12 VoltsAlways Approx.
20-Ground: 4 1 pulse with rotation of rotor shaft
18-Ground: 418 Ohms ON
68 Ohms ON
13-Ground: Always
198 Ohmscontinuity
ONApprox. with cancel SW in control SWApprox. with Res/ACC SW in control S
2-Ground:
"P" "N"Continuity with clutch pedal depressed (M/T)Continuity with shift lever at or position
19-Ground: ONContinuity with cruise control main SW

Cruise Control (Part 1 Of 2)

Cruise Control (Part 2 Of 2)
> Cruise Control > System Information > Diagrams > Page 4131
Cruise Control: Description and Operation

STOP TERMINAL 2
ON GAUGE TERMINAL 12
ECU-IG TERMINAL 14
ON ON TERMINAL 15
TERMINAL 13 --> GROUND
GAUGE TERMINAL 12
--> TERMINAL 15 -->TERMINAL 7 --> TERMINAL 13 --> GROUND
Current is applied at all times through fuse to of stop light switch.With the ignition switch turned to , the current flows
1. SET OPERATION
ON
40Kph, 25mph 200Kph, 124mph TERMINAL 19
When the cruise control main switch is turned and the set switch is pushed with the vehicle speed within the set l
2. SET SPEED CONTROL
TERMINAL 20
TERMINAL 12 -->TERMINAL 6 --> TERMINAL 7 --> TERMINAL 11
TERMINAL 11 --> TERMINAL 7

--> TERMINAL 6 --> TERMINAL 12
During cruise control driving, the ECU compares the set speed memorized in the ECU with the actual vehicle spe
3. COAST CONTROL
ON
During the cruise control driving, while the coast switch is , the cruise control actuator returns the throttle cable t
4. ACCEL CONTROL
ON
During cruise control driving, while the Accel switch is turned , the cruise control actuator pulls the throttle cable
5. RESUME CONTROL
40Kph
Unless the vehicle speed falls below the minimum speed limit (Approx. ) after canceling the speed by the cancel
6. MANUAL CANCEL MECHANISM
If any the following operations occurs during cruise control operation, the magnetic clutch of the actuator turns o
^ ON TERMINAL 2 "N"
ON TERMINAL 2Depressing the clutch pedal (cruise control clutch switch ). "signal input to of ECU" (
^ ON TERMINAL 16Depressing the brake pedal (stop light switch ). "signal input to of ECU"
^ ON TERMINAL 18Push the cancel switch (cancel switch ). "signal input to .
7. AUTO CANCEL FUNCTION

A. If any of the following operate conditions occurs during cruise control operation, the set speed is erased, curre
ONstopped and the cruise control is released. (Main switch turns off). When this occurs, the ignition switch m
ON ON
B. If any of thecurrent
^ Over following conditions
to transistor occurmotor
driving duringand/or
cruisemagnetic
control operation, the setthe
clutch.^ When speed is erased
current and the
continued cruise
to flow to c
"ON"magnetic clutch is cut off until the set switch is again.)
40Kph 25mph
16Kph 10mph ON
^ When the vehicle speed fails below the minimum limit, Approx. ()^ When the vehicle speed falls more
C) If any of the following conditions occurs during cruise control operation, the cruise control is released.
TERMINAL 16^ Open circuit for of cruise control ECU.
> Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection
ABS Light: Testing and Inspection

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 thi
WIRING DIAGRAM
Troubleshoot in accordance with the chart below for each trouble symptom.
Step 1
> Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Page 4136

Step 2
Step 3
> Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Testing and Inspection > Page 4137

Step 4
Step 5
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Interior - Cigarette Lighter Service
Cigarette Lighter: Technical Service BulletinsInterior - Cigarette Lighter Service
ELECTRICALEL002-98
April 10, 1998
Title:CIGARETTE LIGHTER SERVICE
Models:All Models
Introduction
When receiving customer complaints to repair the lighter or lighter socket, please carefully investigate the cause of the
Service Procedure
1. Determine if the lighter is original equipment by using the specifications shown.
a.
If the vehicle has a non-genuine lighter element, it has the possibility to cause a short circuit between the lig
b. A non-genuine lighter element may cause a rattle or bend the socket bimetal contacts.
c. If a non-genuine lighter element is being used, advise the customer to use an original equipment element.
2.
If the lighter element is original equipment and the lighter socket is bent or pulled out of the dash, please ask the
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Technical Service Bulletins > Interior - Cigarette Lighter Service > Page
4142

a.
The specifications in the drawing provide the maximum recommended size of accessory plug. If the custom
b. Using a power plug larger than the given dimensions may damage the lighter socket.
c. If the vehicle has a power point socket, advise the customer to use this socket instead of the lighter socket.
Affected Vehicles
^ All models, all model years
> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
Ground Points
Ground Points

> Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 4145




Parts Location
Parts Location


Service Hints
C 5 CIGARETTE LIGHTER
12 Volts ACC ON
2-Ground: Approx. with Ignition SW at or position1-Ground: Always Continuity
C 8 CLOCK
12 Volts
12 Volts ACC ON
3-Ground: Always Approx. (Power For Clock)5-Ground: Approx. with Ignition SW at or position (Power For
Cigarette Lighter: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Cigarette Lighter And Clock-Connectors

Cigarette Lighter And Clock
> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions
Clock: Diagram Information and Instructions
Ground Points
Ground Points

> Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Diagrams > Diagram Information and Instructions > Page 4167




Parts Location
Parts Location


Service Hints
C 5 CIGARETTE LIGHTER
12 Volts ACC ON
2-Ground: Approx. with Ignition SW at or position1-Ground: Always Continuity
C 8 CLOCK
12 Volts
12 Volts ACC ON
3-Ground: Always Approx. (Power For Clock)5-Ground: Approx. with Ignition SW at or position (Power For
Clock: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Cigarette Lighter And Clock-Connectors

Cigarette Lighter And Clock
> Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions
Door/Trunk Ajar Indicator/Lamp: Diagram Information and Instructions
Ground Points
Ground Points

> Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page
4193

4194

4195

4196

Parts Location
Parts Location
4197

4198

4199

4200

Service Hints
B 7 BUCKLE SW LH
INTEGRATION RELAY
4201

System Outline

ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4202
Door/Trunk Ajar Indicator/Lamp: Diagnostic Aids
4203

4204

4205

Special Tool

4206

HINT:
"Case 1"
"Case 2"

: Connector Body
4207

"Case 1"
HINT:
"Case 2"
4208

Terminal Retainer
Locking Lug

HINT:
4209


4210

CAUTION:
Voltage Check
ON
4211

Voltage Check
ON

> Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Diagrams > Page 4214
Door/Trunk Ajar Indicator/Lamp: Description and Operation


ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair
CAUTION:
90 seconds
90seconds

4. 6
> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions
Seat Belt Reminder Buzzer: Diagram Information and Instructions
Ground Points
Ground Points
System Outline

ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
Parts Location
> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Diagram Information and Instructions > Page 4223

Parts Location



Service Hints
B 7 BUCKLE SW LH
INTEGRATION RELAY






Seat Belt Reminder Buzzer: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON

> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Diagrams > Page 4244
Seat Belt Reminder Buzzer: Description and Operation


ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions
Seat Belt Reminder Lamp: Diagram Information and Instructions

> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4249




Parts Location
Parts Location




Service Hints
B 7 BUCKLE SW LH
INTEGRATION RELAY

System Outline

ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
Ground Points
Ground Points
Seat Belt Reminder Lamp: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON

> Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Diagrams > Page 4270
Seat Belt Reminder Lamp: Description and Operation


ON GAUGE TERMINAL 9
4-8 seconds ON
ON OFF ON
> Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions
Backup Lamp: Diagram Information and Instructions
Ground Points
Ground Points
> Lighting and Horns > Backup Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4276




Parts Location
Parts Location




Splice Points
Splice Points

Backup Lamp: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Back-Up Light-Connectors
Backup Lamp: Electrical Diagrams
Service Hints
B 1-A BACK-UP LIGHT SW (M/T)P 1-B, C BACK-UP LIGHT SW [PARK/NEUTRAL POSITION SW] (A/T)
RA-2-A-1, B-2-B-8, C-6-C-5: Closed with shift lever in position
Back-Up Light
> Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions
Brake Lamp: Diagram Information and Instructions
> Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4301

Ground Points
Ground Points



Parts Location

Parts Location



Splice Points

Splice Points

Brake Lamp: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Stop Light-Connectors
Brake Lamp: Electrical Diagrams
Service Hints
S 7 STOP LIGHT
1-2: Closed with brake pedal depressed
Stop Light
> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations

> Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Locations > Page 4325



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions
Dome Lamp: Diagram Information and Instructions
Parts Location
Parts Location
> Lighting and Horns > Dome Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 4334




Ground Points
Ground Points





Splice Points
Splice Points

Dome Lamp: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Interior Light-Connectors
Dome Lamp: Electrical Diagrams
Service Hints
D 9, D10, D11, D12 DOOR COURTESY SW
1-Ground: Closed with door open
L 4 LUGGAGE COMPARTMENT LIGHT SW (S/D)

1-Ground: Closed with luggage compartment door open
L 4 LUGGAGE COMPARTMENT LIGHT SW (W/G)

1-2: Closed with back door open

Interior Light
> Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions
Hazard Warning Lamps: Diagram Information and Instructions
Ground Points
Ground Points
> Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 4361






Parts Location
Parts Location





Splice Points
Splice Points

Hazard Warning Lamps: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Turn Signal And Hazard Warning Light-Connectors

Hazard Warning Lamps: Electrical Diagrams
Service Hints
T 5 TURN SIGNAL FLASHER
12 Volts ON
ON 12 0 Volts ON
ON 2-Ground: Approx. with ignition SW or Hazard SW 1-Ground: Changes from to with ignition SW and tur

Turn Signal And Hazard Warning Light
> Lighting and Horns > Headlight <--> [Headlamp] > Headlamp Relay > Component Information > Locations

> Lighting and Horns > Headlight <--> [Headlamp] > Headlamp Relay > Component Information > Locations > Page 4390



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Horn > Horn Relay > Component Information > Locations

> Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 4399



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Locations > Page 4408



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 4416



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 4424



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations

> Lighting and Horns > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Locations > Page 4432



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Technical Service Bulletins > Instruments - Turn Signal Operation Imp
ELECTRICALEL004-97
April 25, 1997
V.I.N. PLANT
Parts Information
^
> Lighting and Horns > Taillight <--> [Tail Lamp] > Tail Lamp Relay > Component Information > Locations

> Lighting and Horns > Taillight <--> [Tail Lamp] > Tail Lamp Relay > Component Information > Locations > Page 4446



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Technical Service Bulletins > Instruments - Turn Signal Operation Improved
ELECTRICALEL004-97
April 25, 1997
V.I.N. PLANT
Parts Information
^
> Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions
Heated Glass Element: Diagram Information and Instructions
Ground Points
Ground Points
> Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 4461







Parts Location
Parts Location




Splice Points
Splice Points

Heated Glass Element: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Rear Window Defogger-Connectors

Heated Glass Element: Electrical Diagrams
Service Hints
DEFOGGER RELAY
3-5: ON ONClosed with ignition SW and Rear window defogger SW
R 4 REAR WINDOW DEFOGGER SW

12 Volts ON
5-Ground: Approx. with ignition SW at position4-Ground: Always continuity

Rear Window Defogger
> Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations

> Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 4489



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations

> Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 4498



Details

Body (Fig 19)

Body (Fig 19)
Locations
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for P
Jul > 97 > Windows - Power Window Switch Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
Models:
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
NOTE:
> Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Windo
Windows - Power Window Switch Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
Models:
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
NOTE:
> Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > Customer Interest for Power Window Switch: > EL005-97 > Jul > 97
Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
Models:
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
NOTE:
> Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Window Switch: > EL005-9
Window Switch Inoperative
ELECTRICALEL005-97
July 4, 1997
Title:
Models:
ENGINE STARTING VIN
4AFE 2T1B*02E*VC182750
7AFE 2T1B*02E*V01 91912
Repair Procedure
NOTE:
> Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Windows - Improved Performance In Cold Climate
Window Track: Technical Service BulletinsWindows - Improved Performance In Cold Climate

BODY: BO001-97
February 7, 1997
Title:REAR DOOR GLASS PERFORMANCE IN COLD CLIMATE
Models:'95-'96 Corolla
Introduction
To enhance the performance of the rear door glass on 1995 - 1996 NUMMI Corollas in cold climates, revisions to the m
NOTE:
Service part is NOT affected
1996 NUMMI Corollas starting with VIN 1NX*****TZ482083
Parts Information
Field Fix Procedures

Remove and replace the rear door glass assembly with service part:
1. Remove door trim panel.
2. Remove rear door quarter glass and vertical channel.
3. Remove window regulator bolts.
4. Remove door glass.
Reverse procedure to reinstall rear door glass.

> Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Motor: Diagram Information and Instructions
Ground Points
Ground Points
> Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4540




Parts Location
Parts Location




Splice Points
Splice Points



Ground Points

Ground Points



Parts Location
Parts Location




Splice Points
Splice Points

Windshield Washer Motor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Windshield Washer Motor: Connector Views
Front Wiper And Washer-Connectors
Rear Wiper And Washer-Connectors

Windshield Washer Motor: Electrical Diagrams
Front Wiper and Washer

C14 WIPER AND WASHER SW [COMB. 8W]
12 Volts ON16-Ground: Always continuous.18-Ground: Approx. with ignition SW at position.

12 Volts LOW7-Ground: Approx. with wiper and washer SW at position.
12 Volts MIST
12 Volts 1 10 seconds INT
Approx. with wiper and washer SW at position (W/ mist SW)Approx. every Approx. to intermittent
12 Volts INT4-Ground: Approx. with ignition SW ON unless wiper and washer SW at position.
12 Volts HIGH13-Ground: Approx. with ignition SW ON and wire and washer SW at position.
F 7 FRONT WIPER MOTOR

STOP 5-6:Closed unless wiper motor at position.
Rear Wiper and Washer

R14 REAR WIPER RELAY
12 Volts ON
4 secondswith
3-Ground: Approx. ONignition
INTPoints
SW changes every approx. intermittently with ignition SW and wiper SW at p
at position3-4:
W 1 WASHER MOTOR
12 Volts ON
ON2-Ground: Approx. with ignition SW at position3-Ground: Continuity with washer SW turned

Front Wiper And Washer

Rear Wiper And Washer
> Wiper and Washer Systems > Windshield Washer Motor > Component Information > Description and Operation > Front Wiper and Washer
Windshield Washer Motor: Description and OperationFront Wiper and Washer

TERMINAL 6 With the ignition SW turned on, the current flows to of the wiper and washer SW, of the washer motor
1. LOW SPEED POSITION

TERMINAL 18
--> TERMINAL 7 --> TERMINAL3 --> TERMINAL 1 GROUNDWith wiper SW turned to low position, the
2. HIGH SPEED POSITION
HIGH TERMINAL 18
--> TERMINAL 13 -->TERMINAL 2 --> TERMINAL 1 GROUNDWith wiper SW turned to position, the cu
3. INT POSITION(W/ INTERMITTENT OPERATION)

INT TERMINAL 18
--> TERMINAL 16 --> GROUND
TERMINAL 18 --> TERMINAL 7 --> TERMINAL 3 --> TERMINAL 1 -->
GROUND
With wiper SW turned to position, the relay operates and the current which is connected by relay function flows
4. MIST POSITION(W/ MIST SW)
TERMINAL 18
--> TERMINAL 7 --> TERMINAL3 --> TERMINAL 1 --> GROUND With wiper SW turned to mist positio
5. WASHER CONTINUOUS OPERATION

ON TERMINAL 2 --> TERMINAL 1 --> TERMINAL 8
TERMINAL 18 --> TERMINAL 7 --> TERMINAL 3
TERMINAL 1 --> GROUNDWith washer SW turned to , the current flows from of the washer motor of the wi
6. WASHER OPERATION(W/O WASHER CONTINUOUS CONTROL)
With the washer SW turned to ON, the current flows from of the washer motor of thewiper and washer SW to an
> Wiper and Washer Systems > Windshield Washer Motor > Component Information > Description and Operation > Front Wiper and Washer > Page 4573
Windshield Washer Motor: Description and OperationRear Wiper and Washer

ON TERMINAL 2 TERMINAL 3 TERMINAL 4
When the ignition SW is turned , current flows to of washer motor, of rear wiper relay and of rearwiper motor through
1. REAR WIPER NORMAL OPERATION

ON ON TERMINAL 3
TERMINAL 6 TERMINAL 1 --> TERMINAL 16 GROUND
TERMINAL 3 terminal 4 --> TERMINAL 3 --> --> GROUND
With the ignition SW turned and wiper and washer SW turned , the current flowing to of rear wiper relay flows
2. REAR WIPER INTERMITTENT OPERATION
ON INT TERMINAL 3
TERMINAL 2 --> TERMINAL 10 --> TERMINAL 16 --> GROUND
4 Sec TERMINAL 3 --> TERMINAL 4 --> TERMINAL 3 -->
--> GROUND
TERMINAL 4 --> TERMINAL 1 --> TERMINAL 5 --> TERMINAL 4 --> TERMINAL 3
--> GROUND
TERMINAL 5
TERMINAL 3 TERMINAL 2 --> TERMINAL 10

TERMINAL 3 TERMINAL 4 --> TERMINAL 3 --> --> GROUND
With the ignition SW turned and wiper and washer SW turned to position, the current flowing to of rear wiper r
3. WASHER OPERATION
ON ON TERMINAL 2
OFF
OFFWith the ignition SW and the rear wiper and washer SW is turned strongly (Washer SW ), current flows fro
> Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Windshield Wiper Blade - Maintenance and Cleaning
Wiper Blade: Technical Service BulletinsWindshield Wiper Blade - Maintenance and Cleaning
BODYBO030-01
Title:WINDSHIELD WIPER BLADE MAINTENANCE AND CLEANING
Models:All Models
December 7, 2001
Introduction
The following procedures are recommended to maintain windshield wiper blade performance.
All models.
Applicable Vehicles^
Maintenance, Cleaning and UseRecommendations for Windshield Wiper Maintenance, Cleaning and Use:
1. Scheduled Maintenance
^ Check wiper rubber blades every 4 - 6 months or 7,500 miles for wear, cracking and contamination.
^
Clean glass and rubber wiper blades if blades are not clearing glass adequately. If this does not correct the pro
2. Cleaning Procedure
^ Wiper Rubber: Bugs, dirt, sap and road grime on blades will cause streaking.
^ Clean wiper rubber of road and environmental debris using cloth or paper towel soaked with windshield wash
^8DO NOT USE fuel, kerosene, or petroleum based products to clean rubber wiper blades.
^ Windshield: Bugs, road grime, sap and car wash wax treatments decrease wiper performance.
^ Rinse windshield with water and apply non-abrasive cleaner, such as Bon-Ami (www.faultless.com), with a s
NOTE:
Make sure to use plenty of water with all powder based cleaners so the glass is not scratched.
3. Contributors to Poor Performance/Decreased Rubber Blade Life (require rubber replacement)

^ Dusty areas cause the rubber edge to wear quickly.
^
Sand and salt used for road conditioning during winter causes the edge to wear quickly, so areas with significa
^
Heat and time cause the rubber to become excessively "permanent set," so the rubber does not turn over, resul
^ Rubber is easily cut or torn while using ice scrapers on the glass.
^ Rubber can be torn when pulling blades off a frozen windshield.
> Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Windshield Wiper Blade - Maintenance and Cleaning > Page 4578

^ Using wipers instead of an ice scraper to remove frost and ice from the windshield during a car warm up can d
^
Banging wiper on the glass to remove ice & snow can cause the blade to bend and rubber to come out of the b
^
Ice forms in wiper blade pin joints, which causes streaking and unwiped areas. To remove ice from pin joints,
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Instruments - Wiper Motor Circuit Breaker Inspection
Wiper Motor: Technical Service BulletinsInstruments - Wiper Motor Circuit Breaker Inspection
REF.: ELECTRICAL
NO.: EL95-004
MODEL: ALL MODELS
WIPER MOTOR CIRCUIT BREAKER INSPECTION PROCEDURE
To eliminate the possibility of Wiper Motor damage, all ND Wiper Motors are equipped with circuit breaker protection
This circuit breaker is a thermal limiting type and will reset automatically after the Wiper Motor current load returns to
REPRESENTATIVE LOCATION OF CIRCUIT BREAKER:
Inspect the Wiper

INSPECTION Fuse.
PROCEDURE:^
^ Verify there is power and ground to the Wiper Motor on all speeds (including "Intermittent" or "Mist" if applicable
After verifying power and ground to the Wiper Motor, follow the procedure below to prevent unnecessary Wiper Moto
1) Disconnect the Wiper Motor Harness Connector.
2) Wait (10) minutes before checking continuity.
3) Check the continuity of the motor with an ohmmeter.
If there is no continuity in the Wiper Motor after 10 minutes, replace the Wiper Motor.
REPRESENTATIVE CHECKING PROCEDURE:
> Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Instruments - Wiper Motor Circuit Breaker Inspection > Page 4583

NOTE:
Continuity check can be performed between either the low speed or high speed terminal and the ground terminal of
> Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions
Wiper Motor: Diagram Information and Instructions
Ground Points
Ground Points
> Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 4586




Parts Location
Parts Location




Splice Points
Splice Points



Ground Points

Ground Points



Parts Location
Parts Location




Splice Points
Splice Points

Wiper Motor: Diagnostic Aids



Special Tool


HINT:
"Case 1"
"Case 2"

: Connector Body

"Case 1"
HINT:
"Case 2"

Terminal Retainer
Locking Lug

HINT:



ON
CAUTION:
Voltage Check

Voltage Check
ON
Wiper Motor: Connector Views
Front Wiper And Washer-Connectors
Rear Wiper And Washer-Connectors

Wiper Motor: Electrical Diagrams
Front Wiper and Washer

C14 WIPER AND WASHER SW [COMB. 8W]
12 Volts ON16-Ground: Always continuous.18-Ground: Approx. with ignition SW at position.

12 Volts LOW7-Ground: Approx. with wiper and washer SW at position.
12 Volts MIST
12 Volts 1 10 seconds INT
Approx. with wiper and washer SW at position (W/ mist SW)Approx. every Approx. to intermittent
12 Volts INT4-Ground: Approx. with ignition SW ON unless wiper and washer SW at position.
12 Volts HIGH13-Ground: Approx. with ignition SW ON and wire and washer SW at position.
F 7 FRONT WIPER MOTOR

STOP 5-6:Closed unless wiper motor at position.
Rear Wiper and Washer

R14 REAR WIPER RELAY
12 Volts ON
4 secondswith
3-Ground: Approx. ONignition
INTPoints
SW changes every approx. intermittently with ignition SW and wiper SW at p
at position3-4:
W 1 WASHER MOTOR
12 Volts ON
ON2-Ground: Approx. with ignition SW at position3-Ground: Continuity with washer SW turned

Front Wiper And Washer

Rear Wiper And Washer
> Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Front Wiper and Washer
Wiper Motor: Description and OperationFront Wiper and Washer

TERMINAL 6 With the ignition SW turned on, the current flows to of the wiper and washer SW, of the washer motor
1. LOW SPEED POSITION

TERMINAL 18
--> TERMINAL 7 --> TERMINAL3 --> TERMINAL 1 GROUNDWith wiper SW turned to low position, the
2. HIGH SPEED POSITION
HIGH TERMINAL 18
--> TERMINAL 13 -->TERMINAL 2 --> TERMINAL 1 GROUNDWith wiper SW turned to position, the cu
3. INT POSITION(W/ INTERMITTENT OPERATION)

INT TERMINAL 18
TERMINAL 18 --> TERMINAL 7 --> TERMINAL 3 --> TERMINAL 1 -->
GROUND
With wiper SW turned to position, the relay operates and the current which is connected by relay function flows
4. MIST POSITION(W/ MIST SW)
TERMINAL 18
--> TERMINAL 7 --> TERMINAL3 --> TERMINAL 1 --> GROUND With wiper SW turned to mist positio
5. WASHER CONTINUOUS OPERATION

ON TERMINAL 2 --> TERMINAL 1 --> TERMINAL 8
TERMINAL 1 --> GROUNDWith washer SW turned to , the current flows from of the washer motor of the wi
6. WASHER OPERATION(W/O WASHER CONTINUOUS CONTROL)
With the washer SW turned to ON, the current flows from of the washer motor of thewiper and washer SW to an

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toyota :: Toyota Corolla Wagon L4-96.

Door Lock Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Sunroof / Moonroof Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Radiator Cooling Fan Motor Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Blower Motor Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Compressor Clutch Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Condenser Fan Motor Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Control Module HVAC: Testing and Inspection

Inspect A/C Amplifier Circuit

TestON Ignition switch

TestON Ignition switch

Control Module HVAC: Service and Repair

1. Remove Glove Compartment Parts

a. Disconnect the connector.b. Remove the screw and the amplifier.

Daytime Running Lamp Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Headlamp Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Horn Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)

Tail Lamp Relay: Locations

Corolla Wagon L4-96.8 1587cc 1.6L DOHC (4A-FE) (1996)