toyota+yaris+2002++manual++por+alfoxo+en+ingles

TOYOTA REPAIR MANUAL SUPPLEMENT FOR CHASSIS & BODY

FOREWORD This supplement has been prepared to provide information covering general service repairs for the chassis and body of the TOYOTA YARIS/ECHO which underwent changes in September, 2001. Applicable models:

SCP10 series NCP10, 11, 12, 13 series NLP10 series

For the service specifications and repair procedures of the above model other than those listed in this supplement, refer to the following manuals. Manual Name

Pub. No.

• YARIS/ECHO Chassis and Body Repair Manual

RM685E

• YARIS/ECHO Chassisand Body Repair Manual Supplement (Aug., 1999)

RM737E

• YARISIECHO Chassisand Body_RepairManual Supplement (Jan., 2001) _

'.

RM838E

• lSZ-FE Engine Repair Manual

RM686E

• 1SZ-FE Engine Repair Manual Supplement

RM839E

• 1NZ-FE, 2NZ-FE Engine Repair Manual

RM749E

• 1ND- TV Engine Repair Manual

RM920E

• U340E, U341E Automatic Transaxle Repair Manual (Aug., 1999)

RM735U

• U440E, U441E Automatic Transaxle Repair Manual (Jan., 1999)

RM689E

AII information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.

TOYOTA MOTOR CORPORATION

©2003 TOYOTA MOTOR CORPORATION AII rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission 01Toyota Motor Corporation. FirstPrinting: Aug. 1, 2001 01-010801-00 Third Printing: Sep. 8, 2003 03-030908-00-3

CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. •

Must read this manual thoroughly. It is especially important to have a good understanding of all the contents written in the PRECAUTION of "IN" section.

•

The service method written in this manual is very effective to perform repair and service. When performing the operations following the procedures using this manual, be sure to use tools specified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation.

•

If part replacement is necessary, must replace the part with the same part number or equivalent partoDo not replace it with inferior quality.

•

It is important to note that this manual contains various "Cautions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these "Cautions" and "Notices" are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

INTRODUCTION lID PREPARATION ID SERVICE SPECIFICATIONS 1m) OIAGNOSTICS mi CLUTCH 6! C153 MANUAL TRANSAXLE DEi SUSPENSION ANO AXLE mi! BRAKE mi] STEERING Iffi] BOOY ELECTRICAL mal AIR CONDITIONING m!1 ALPHABETICAL INDEX 11m

INTRODUCTION HOW TO USE THIS MANUAL

.

GENERAL INFORMATION

IDENTIFICATION INFORMATION

IN-1 .... .

.

IN-111i1

IN-3

VEHICLE IOENTIFICATION ANO ENGINE SERIAL NUMBER

REPAIR INSTRUCTIONS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . .

1N-3

IN-5 1N-5

VEHICLE LlFT ANO SUPPORT LOCATIONS

FOR ALL OF VEHICLES PRECAUTION

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION . . . . . . . . . . . . . . . . . . .

IN-9

IN-13 IN-13

IN-21 IN-21

HOW TO PROCEEO WITH TROUBLESHOOTING .. .. .. .. . .. .. . .. .. .. .

IN-22

HOW TO USE THE OIAGNOSTIC CHART ANO INSPECTION PROCEOURE .;........

TERMS ABBREVIATIONS USEO IN THIS MANUAL

1N-32

IN-37 IN-37

IN-1 INTRODUCTION

-

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL INOOU-31

GENERAL INFORMATION 1. INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every .... page. I.IY 2. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN-22. Be sure to read thís before performing troubleshooting. 4. PREPARATION Preparation llsts the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Specíal Service Materíals) which should be prepared before beginning the operation and explaíns the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: ~Fillercap ~~---Float

SlottedSpring Pin

~

_- --$

Piston

Cylinder

I N'm (kgf'cm, ft-lbf) 1: Specified torque • Non-reusable part

N17080

IN-2 INTRODucnoN

-

HOW TO USE THIS MANUAL

The procedures are presented in a step-by-step format: • The illustration shows what to do and where to do it. • The task heading tells what to do. • The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example:

11

This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type.

6.

REFERENCES

References have been kept to a minimum. However,when they are required you are given the page to refer

too 7.

SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the proeedure to look up your speeifieations. They are also found in Serviee Specifieations seetion for quick referenee.

8. • • •

9.

CAUTIONS,NOTICES,HINTS: CAUTIONS are presented in bold type, and indieate there is a possibility of injury to you or other people. NOTICES are also presented in bold type, and indieate the possibility of damage to the eomponents being repaired. HINTS are separated from the text but do not appear in bold. They provide additional information to help you pertorm the repair efficiently.

SI UNIT

The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metrie system and in the English System. Example: Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

IN-3 INTRODUCTION

-

IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION INQ-06

TORQUE SPECIFICATION Part tightened

N'm

kgl'cm

ft-lbf

54

540

39

AJC unit x Liquid and Suction hose

5.4

55

48 in.·lbl

Expansion valve x Evaporator

3.4

35

30 in.·lbf

Condenser x Liquid tube

5.4

55

48 in.·lbf

Condenser x Oischargehose

5.4

55

48 in.·lbf

Pressure switch x Liquied tube

10

100

7

25

250

18

13.2

135

9

Orive belt ;

Pivot bolts Refrigerant líne

Compressor and magnetic clutch Compressor x Engine Pressure plate x Compressor

- MEMO-

DIAGNOSTICS ANTI-LOCK

BRAKE SYSTEM WITH ELECTRONIC

BRAKE FORCE OISTRIBUTION

(EBO)

(lND-TV)

01-1

HOW TO PROCEEO WITH TROUBLESHOOTING PRE-CHECK

. .

01-1

OIAGNOSTIC TROUBLE COOE CHART

.

CIRCUIT INSPECTION

.

01-5 01-7

ENGINE IMMOBILlSER

SYSTEM

.

DI-2E1

01-15

HOW TO PROCEEO WITH TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK

. .

PRE-CHECK

.

DIAGNOSTIC TROUBLE COOE CHART

.

TERMINALS OF ECU

.

CIRCUIT INSPECTION

.

01-15 01-16 01-17 01-19 01-20 01-21

REFER TO FOLLOWING REPAIR MANUALS: Manual Name

Pub. No.

YARIS / ECHOChassis and BocIyRepair Manual

RM685E

YARIS / ECHOChassis and Body Repair Manual Supplement (Aug., 1999)

RM737E

YARIS / ECHOChassis and Body Repair Manual Supplement (Jan., 2001)

RM838E

NOTE: The above pages contain only the points which differ from the above listed manuals.

DIAGNOSnCS

-

01-1

ANn-lOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBO) (1ND-TV)

ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBO) (1NO- TV) DlltAP~2

HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. ~ehicle Brought to worksho~

I

~ Custom~

1

O

I

~oblem Analysis

~

Items inside are titles of pages in this manual, with the page number in the bottom portion. See the pages tor detailed explanations.

.

2 Symptom does not occur 31'---p-ro-b-le-m-S-ym-Pt-om-c-o-n-tir-m-a-tio-n----,I

> 4 u..1

S_y=m:-p...;._t~.:....;.~:..:...;NS:.....;~~=2=-ul_at_io_

nr

See combination meter troubleshooting (See page BE-4).

6

'R-e-p-a-¡-r -o-r-re-p-I-ace--co-m-b-¡n-a-t-¡o-n-m-et-e-r.------,

Check for open or short circuit in harness and connector (See page IN-32).

E> Check and replace ABS actuator assembly (See page IN-32).

Repair o, ,eplace hamess o, connecto,.

DIAGNOSTICS

..., ANTI-LOCK

BRAKE SYSTEM

WITH ELECTRONIC

01-13

BRAKE FORCE DISTRIBUTION (EBD) (1 NO- TV) Ol8QO.-01

ITe Terminal Cireuit CIRCUIT DESCRIPTION

Connecting between terminals Tc and CG of the DLC3 causes the ECU to display the DTC by flashing the ABS warning light.

WIRING DIAGRAM DLC3

ABS Actuator With ECU

Instrument Panel J/B Th ~1~3

~P_-~B

W-B

~

3

CG~4~--------------~

P-B

8

W-B

IO:LHO IF:RHO N

F16395

01-14

DIAGNOSTlCS

-

ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE OISTRIBUTION (EBO) (1NO-TV)

INSPECTION PROCEDURE 1 f7J\

'V

Check voltage between terminals Tc and CG 01OLC3. CHECK:

ON

(a) Turn the ignition switch ON. (b) Measure voltage between terminals Tc and CG of DLC3. OK:

Te

Voltage: 5.7 - 8.1 V

DLC3

N

F09678

L) K

2

CG are connected,d_o_e_s_n_o_t_b_li_n_k_e_ve_n_a_ft_e_r the ECU may be defec....and I_'A_. _B_s_w_a_r_nI_on_9_I_i9_h_t tive.

Check 10r open and short circuit in harness and connector between skid control ECUand OLC3, OLC3 and body ground (See page 1N-32).

G Check and replace ABS actuator (See page 1N-32).

assembly

Repa!ror replace hamess or connector.

01-15 DIAGNOSTICS -

ENGINE IMMOBILlSER SYSTEM

ENGINE IMMOBILISER SVSTEM OI67Z-{)4

HOW TO PROCEED WITH TROUBLESHOOTING Troubleshoot in accordance with the procedure on the following pages. (yehicle Brought to worksho~

1

~ Customer proglem Analysis

I

_

P. DI-1

21 _

Check ant ?~ear

P.0-

Items inside D are titles of pages in this manual, with the page number in the bottom portion. See the pages for detailed explanations.

1: _

D¡~

jPre check)!

.71

,01- 6

Symptom does not occur 3 r-I-P-r-ob-I-em-S-y-m-pt-o-m-C-o-n-fir-m-a-tio-n----,I

>

4/_--=.SL.:ym..:.:Jpr:..::~.~0~:..:..:.N-;:~2:..:.:.i~:..:.;u::.:.la=..:t::..

nU

. nsympto. m occurs

51 &

~~.==============~ OTC Check ~p~0~1-~17~.~0~1-~27~6~* ~íCI

J1

JI

Normal code

=============1l~..

Malfunction code

6/_~0~T~c~c~h=a~rt~~~---I_ P. 01-19. 01-279*

8

71· _

_

I

Problem Symptoms Table P.01-282* _

Circuit Inspection and Part Inspection P. 01-21 - 01-28, 01-283 - 01-290* *: See Pub No. RM685E Identification of Problem

9

I

Repair

I

~

1°1_

Confirmation Test Step 2, 5: Oiagnostic steps permitting the use 01 the hand-held tester or break-out-box.

(

End

)

01-16 DIAGNOSTICS

-

ENGINE IMMOBILlSER SYSTEM 01680-02

CUSTOMER PROBLEM ANALVSIS CHECK

I ENGINE IMMOBILISER

Check Sheet

I

Inspector's . Name .

Registration No. Registration Year

Customer's Name

I

I

Frame No. Date Vehicle Brought In

I

Date Problem First Occurred Frequency Problem Occurs

km miles

Odometer Reading

I

I O

I [J

Continuous

Intermittent (

times a day)

Immobiliser is not set. O (Engine starts with key codes otherthan the registered key code.) Symptoms O Engine does not start.

Check Item

Malfunction Indicator Lamp

O Normal

O RemainsON

O Ooes not Light Up

1st Time

O

Normal Code

O

Malfunction Code (Code

)

2nd Time

O

Normal Code

[J

MalfunctionCode (Code

)

DTC Check

01-17 DIAGNOSTlCS

-

ENGINE IMMOBILlSER SYSTEM DlaRo....en

Hand-held

PRE-CHECK 1. (a)

N

112054

(b)

1ND-TV: DIAGNOSIS SYSTEM Description ECU controls the function ot immobiliser on this vehicle. Data of the immobiliser or DTC can be read form DLC3 of the vehicle. When a trouble occurs on immobiliser, MIL does not light up but DTC inspection is performed. Therefore when there seems to be a trouble on immobiliser, use hand-held tester or SST to check and troubleshoot it.

Check the DLC3. The vehicle's engine ECU uses ISO 14230 tor communication. The terminal arrangement 01 DLC3 complies with SAE J1962 and matches the ISO 14230 format.

OLC3 A04550

Terminal No.

Connection / Voltage or Resistance

Condition

7

Bus $ Une / Pulse generation

During transmission

4 16

Chassis Ground

H

Body Ground / 1 .Q or less

Battery Positiva H Body Ground / 9 - 14 V

Always Always

HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable 01 the hand-held tester to DLC3, turned the ignition switch ON and operated the handheld tester, there is a problem on the vehicle side or tool side. • If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. • If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department lísted in the tool's instruction manual.

01-18 DIAGNOSTICS

2.

-

ENGINE IMMOBILISER SYSTEM

1ND-TV:

INSPECT DIAGNOSIS (Normal Mode) Check the OTC using hand-held tester. NOTleE:

Hand-held tester only: When the diagnosis system is switched from normal mode to check mode, it erases all DTCsand freezed frame data recorded in normal mode. So befo re switching modes, always check the DTCs and freezedframe data, and note them down. (1) (2) (3) (4)

(5)

Prepare the hand-held tester. Connect the hand-held tester to OLC3. Turn the ignition switch ON and push the hand-held tester main switch ON. Use the hand-held tester to check the OTCs and freezed frame data, note them down. (For operating instructions, see the hand-held tester instruction book.) See page 01-19 to confirm the details of the OTCs.

01-19 DIAGNOSTICS

-

ENGINE IMM081L1SER SYSTEM 01682-03

CIAGNOSTIC TROUBLE COCE CHART 1ND-TV: OTCNo. (See Page) 82795 (01-21)

Oetection Item

Unmatched key code

Trouble Area oKey oUnregistered key insertad before oKey

82796 (01-22)

No communicatíon in immobíliser system

82797 (01-24)

Communícalion malfunction No. 1

82798 (01-26)

Communicatíon malfunction No. 2

oTransponder key amplifíer oWire harness oEngine ECU oCommunicalíon contenta oKey oTransponder key amplifier oWire harness oEngine ECU

HINT: To reduce the unnecessary exchange of engine ECU, check that a trouble occurs with the original engine ECU at the time of excanging engine ECU and the trouble will disappear with a new engine ECU.