Get INTRODUCTION Guide for Toyota Avensis 4 Door First Generation (1997-2003)

INTRODUCTION

HOW TO USE THIS MANUAL . . . . . . . . . . . . .

IN–1

IN–3

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

IDENTIFICATION INFORMATION . . . . . . . . . .

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . .

REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . .

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

VEHICLE LIFT AND

IN–3

IN–4

SUPPORT LOCATIONS . . . . . . . . . . . . . . . . . .

FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . .

PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO TROUBLESHOOT

IN–7

IN–9

ECU CONTROLLED SYSTEMS . . . . . . . . .

GENERAL INFORMATION . . . . . . . . . . . . . . . . . .

HOW TO PROCEED WITH

IN–19

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

HOW TO USE THE DIAGNOSTIC CHART

AND INSPECTION PROCEDURE . . . . . . . . . .

TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABBREVIATIONS USED IN THIS MANUAL . . . .

IN–20

IN–30

IN–35

IN–1

INTRODUCTION

–

HOW TO USE THIS MANUAL

IN00U–65

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.

2.

PRECAUTION

At the beginning of each section, a PRECAUTION 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–20.

Be sure to read this before performing troubleshooting.

4.

PREPARATION

Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-

cial Service Materials) which should be prepared before beginning the operation and explains 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

ClevisPin

Clip

z Gasket

Reservoir Tank

Boot

z Grommet

Slotted Spring Pin

12(120, 9)

Clevis

Lock Nut

15(155,11)

Snap Ring

Washer

Push Rod

Piston

Cylinder

N·m (kgf·cm, ft·lbf)

: Specified torque

z Non–reusable part

N17080

AVENSIS/CORONA SUP (RM781E)

IN–2

INTRODUCTION

–

HOW TO USE THIS MANUAL

The procedures are presented in a step–by–step format:

S

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.

Exampleȧ

Taskheading: what to do

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a) Place SST and a dial indicator onto the overdrive brake pis-

ton as shown in the illustration.

SST 09350–30020 (09350–06120)

Illustration:

what to do and where

Set part No.

Component part No.

Detailed text : how to do task

(b) Measure the stroke applying and releasing the compressed

2

air(392Ċ 785 kPa, 4 Ċ 8 kgf/cm or57Ċ 114psi)asshown

in the illustration.

Piston stroke: 1.40 Ċ 1.70 mm (0.0551 Ċ 0.0669 in.)

Specification

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 informa-

tion. 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

to.

7.

SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the

procedure to look up your specifications. They are also found in Service Specifications section for quick ref-

erence.

8.

CAUTIONS, NOTICES, HINTS:

S

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other

people.

S

NOTICES are also presented in bold type, and indicate the possibility of damage to the components

being repaired.

HINTS are separated from the text but do not appear in bold. They provide additional information to

help you perform the repair efficiently.

9.

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 metric system and in the English System.

Example:

Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)

AVENSIS/CORONA SUP (RM781E)

IN–3

INTRODUCTION

–

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER

IN06B–11

1.

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number is stamped in the engine

compartment. This number has also been stamped on the

manufacturer’s label.

A

A: Vehicle Identification Number

B: Manufacturer’s Label

2.

ENGINE SERIAL NUMBER

B

The engine serial number is stamped on the engine block, as

shown in the illustration.

B02393

1AZ–FSE engine:

1ZZ–FE, 3ZZ–FE engines:

3S–FE engine:

1CD–FTV engine:

B12481

AVENSIS/CORONA SUP (RM781E)

IN–4

INTRODUCTION

–

REPAIR INSTRUCTIONS

IN03Z–03

GENERAL INFORMATION

BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle

clean and prevent damage.

(b) During disassembly, keep parts in the appropriate order

to facilitate reassembly.

(c) Installation and removal of battery terminal:

(1) Before performing electrical work, disconnect the

negative (–) terminal cable from the battery.

(2) If it is necessary to disconnect the battery for in-

spection or repair, first disconnect the negative (–)

terminal.

FI1066

(3) When disconnecting the terminal cable, to prevent

damage to the battery terminal, loosen the cable

nut and raise the cable straight up without twisting

or prying it.

(4) Clean the battery terminals and cable ends with a

clean shop rag. Do not scrape them with a file or oth-

er abrasive objects.

(5) Install the cable ends to the battery terminals after

loosening the nut and tighten the nut after installa-

tion. Do not use a hammer to tap the cable ends

onto the terminals.

(6) Be sure the cover for the positive (+) terminal is

properly in place.

(d) Check hose and wiring connectors to make sure that they

are connected securely and correctly.

(e) Non–reusable parts

(1) Always replace cotter pins, gaskets, O–rings and oil

seals, etc. with new ones.

(2) Non–reusable parts are indicated in the component

illustrations by the ”z” symbol.

(f)

Precoated parts

Precoated parts are bolts and nuts, etc. that are coated

with a seal lock adhesive at the factory.

(1) If a precoated part is retightened, loosened or

caused to move in any way, it must be recoated with

the specified adhesive.

(2) When reusing precoated parts, clean off the old

adhesive and dry with compressed air. Then apply

the specified seal lock adhesive to the bolt, nut or

threads.

(3) Precoated parts are indicated in the component il-

lustrations by the ”L” symbol.

(g) When necessary, use a sealer on gaskets to prevent

leaks.

AVENSIS/CORONA SUP (RM781E)

IN–5

INTRODUCTION

–

REPAIR INSTRUCTIONS

(h) Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.

(i)

Use of special service tools (SST) and special service ma-

terials (SSM) may be required, depending on the nature

of the repair. Be sure to use SST and SSM where speci-

fied and follow the proper work procedure. A list of SST

and SSM can be found in Preparation section in this

manual.

(j)

When replacing fuses, be sure the new fuse has the cor-

rect amperage rating. DO NOT exceed the rating or use

one with a lower rating.

Medium Current Fuse and High Current Fuse

EqualAmperageRating

BE1367

Illustration

Symbol

Part Name

Abbreviation

FUSE

MEDIUM CURRENT FUSE

HIGH CURRENT FUSE

FUSIBLE LINK

M–FUSE

H–FUSE

FL

CIRCUIT BREAKER

CB

V00076

(k) Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the prop-

er locations (See page IN–7).

(1) If the vehicle is to be jacked up only at the front or

rear end, make sure to place the stopper under the

wheels at the opposite end to block them in order to

ensure safety.

AVENSIS/CORONA SUP (RM781E)

IN–6

INTRODUCTION

–

REPAIR INSTRUCTIONS

(2) After the vehicle is jacked up, be sure to support it

on stands. It is extremely dangerous to do any work

on a vehicle raised on a jack alone, even for a small

job that can be finished quickly.

(l)

Observe the following precautions to avoid damage to the

following parts:

(1) Do not open the cover or case of the ECU unless

absolutely necessary. (If the IC terminals are

touched, the IC may be destroyed by static electric-

ity.)

(2) To disconnect vacuum hoses, pull off the end, not

the middle of the hose.

WRONG

CORRECT

(3) To pull apart electrical connectors, pull on the con-

nector itself, not the wires.

(4) Be careful not to drop electrical components, such

as sensors or relays. If they are dropped on a hard

floor, they should be replaced and not reused.

(5) When steam cleaning an engine, protect the elec-

tronic components, air filter and emission–related

components from water.

IN0253

(6) Never use an impact wrench to remove or install

temperature switches or temperature sensors.

(7) When checking continuity at the wire connector, in-

sert the tester probe carefully to prevent terminals

from bending.

WRONG

CORRECT

(8) When using a vacuum gauge, never force the hose

onto a connector that is too large. Use a step–down

adapter for adjustment. Once the hose has been

stretched, it may leak air.

IN0252

(m) Installation and removal of vacuum hose:

(1) When disconnecting vacuum hoses, use tags to

identify where they should be reconnected to.

(2) After completing a job, double check that the vacu-

um hoses are properly connected. A label under the

hood shows the proper layout.

Example

(n) Unless otherwise stated, all resistance is measured at an

ambient temperature of 20°C (68°F). Because the resis-

tance may be outside specifications if measured at high

temperatures immediately after the vehicle has been run-

ning, measurement should be made when the engine has

cooled down.

IN0002

AVENSIS/CORONA SUP (RM781E)

IN–7

INTRODUCTION

–

REPAIR INSTRUCTIONS

IN040–06

VEHICLE LIFT AND SUPPORT LOCATIONS

Front

JACK POSITION

Front

Rear

Front center member

Rear suspension member

CAUTION : When jacking–up the rear and front, make sure the car is not

carrying any extra weight.

PANTOGRAPH JACK POSITION

SUPPORT POSITION

Safety stand and swing arm type lift

B02394

AVENSIS/CORONA SUP (RM781E)

IN–8

INTRODUCTION

–

REPAIR INSTRUCTIONS

PLATE TYPE LIFT

ȏ

B

Attachment

A

C

HINT :

Left and right set position

Place the vehicle over the center of the lift.

D Align the cushion gum ends of the plate

Front and rear set position

with the attachment lower ends (A, C).

D Align the attachment upper end (B) with the

front jack supporting point (ȏ).

Attachment dimensions

85 mm (3.35in)

70 mm (2.76 in)

100 mm (3.94 in)

200 mm (7.87 in)

B02395

AVENSIS/CORONA SUP (RM781E)

IN–9

INTRODUCTION

–

FOR ALL OF VEHICLES

IN0HV–01

PRECAUTION

1.

FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND

SEAT BELT PRETENSIONER

(a) The AVENSIS/CORONA is equipped with an SRS (Sup-

plemental Restraint System), such as the driver airbag,

front passenger airbag, side airbags, curtain shield airbag

and seat belt pretensioners.

Failure to carry out service operations in the correct se-

quence could cause the supplemental restraint system to

unexpectedly deploy during servicing, possibly leading to

a serious accident.

Further, if a mistake is made in servicing the supplemental

restraint system, it is possible the SRS may fail to operate

when required. Before servicing (including removal or

installation of parts, inspection or replacement), be sure

to read the following items carefully, then follow the cor-

rect procedure described in this manual.

(b) GENERAL NOTICE

Negative Cable

(1) Malfunction symptoms of the supplemental re-

straint system are difficult to confirm, so the diag-

nostic trouble codes become the most important

source of information when troubleshooting. When

troubleshooting the supplemental restraint system,

always inspect the diagnostic trouble codes before

disconnecting the battery (See Pub. No. RM599E,

page DI–152).

BO4111

(2) Work must be started after 90 seconds from the

time the ignition switch is turned to the ”LOCK” posi-

tion and the negative (–) terminal cable is discon-

nected from the battery.

(The supplemental restraint system is equipped

with a back–up power source so that if work is

started within 90 seconds of disconnecting the neg-

ative (–) terminal cable from the battery, the SRS

may deploy.)

When the negative (–) terminal cable is discon-

nected from the battery, memory of the clock and

audio systems will be cancelled. So before starting

work, make a record of the contents memorized by

the each memory system. Then when work is fin-

ished, reset the clock and audio systems as before.

To avoid erasing the memory of each memory sys-

tem, never use a back–up power supply from out-

side the vehicle.

AVENSIS/CORONA SUP (RM781E)

IN–10

INTRODUCTION

–

FOR ALL OF VEHICLES

(3) Even in cases of a minor collision where the SRS

does not deploy, the steering wheel pad (See Pub.

No. RM599E, page RS–15), front passenger airbag

assembly (See Pub. No. RM599E, page RS–28),

side airbag assemblies (See Pub. No. RM698E,

page RS–11), curtain shield airbag assemblies

(See Pub. No. RM698E, page RS–25) and seat belt

pretensioners (See Pub. No. RM599E, page

BO–152) should be inspected.

(4) Never use SRS parts from another vehicle. When

replacing parts, replace them with new parts.

(5) Before repairs, remove the airbag sensor if shocks

are likely to be applied to the sensor during repairs.

(6) Never disassemble and repair the airbag sensor as-

sembly, side airbag sensor assembly, steering

wheel pad, front passenger airbag, side airbag or

seat belt pretensioner in order to reuse them.

(7) If the airbag sensor assembly, side airbag sensor

assembly, steering wheel pad, front passenger air-

bag, side airbag or seat belt pretensioner have

been dropped, or if there are cracks, dents or other

defects in the case, bracket or connector, replace

them with new ones.

(8) Do not directly expose the airbag sensor assembly,

side airbag sensor assembly, steering wheel pad,

front passenger airbag, side airbag or seat belt pre-

tensioner to hot air or flames.

(9) Use a volt/ohmmeter with high impedance (10 kΩ/V

minimum) for troubleshooting of the electrical cir-

cuit.

(10) Information labels are attached to the periphery of

the SRS components. Follow the instructions on the

notices.

(11) After work on the supplemental restraint system is

completed, check the SRS warning light (See Pub.

No. RM599E, page DI–152).

(c) SPIRAL CABLE (in Combination Switch)

The steering wheel must be fitted correctly to the steering

column with the spiral cable at the neutral position, other-

wise cable disconnection and other troubles may result.

Refer to Pub. No. RM599E, page SR–18 of this manual

concerning correct steering wheel installation.

Match marks

R11910

AVENSIS/CORONA SUP (RM781E)

IN–11

INTRODUCTION

–

FOR ALL OF VEHICLES

(d) STEERING WHEEL PAD (with Airbag)

(1) When removing the steering wheel pad or handling

a new steering wheel pad, it should be placed with

the pad top surface facing up.

Storing the pad with its metallic surface facing up-

ward may lead to a serious accident if the airbag in-

flates for some reason. In addition do not store a

steering wheel pad on top of another one.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very

dangerous.)

(3) Grease should not be applied to the steering wheel

pad and the pad should not be cleaned with deter-

gents of any kind.

(4) Store the steering wheel pad where the ambient

temperature remains below 93°C (200°F), without

high humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) under the

steering column near the combination switch con-

nector before starting work.

(6) When disposing of a vehicle or the steering wheel

pad alone, the airbag should be deployed using an

SST before disposal (See Pub. No. RM599E, page

RS–17).

Carry out the operation in a safe place away from

electrical noise.

Example:

Correct

Wrong

B02401

Example:

Z13950

AVENSIS/CORONA SUP (RM781E)

IN–12

INTRODUCTION

–

FOR ALL OF VEHICLES

(e) FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always store a removed or new front passenger air-

bag assembly with the airbag deployment direction

facing up.

Storing the airbag assembly with the airbag deploy-

ment direction facing down could cause a serious

accident if the airbag inflates.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very

dangerous.)

(3) Grease should not be applied to the front passen-

ger airbag assembly and the airbag door should not

be cleaned with detergents of any kind.

(4) Store the airbag assembly where the ambient tem-

perature remains below 93°C (200°F), without high

humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) installed on

the assembly before starting work.

(6) When disposing of a vehicle or the airbag assembly

alone, the airbag should be deployed using an SST

before disposal (See Pub. No. RM599E, page

RS–30).

Perform the operation in a safe place away from

electrical noise.

Example:

Correct

Wrong

B02402

Example:

B02404

AVENSIS/CORONA SUP (RM781E)

IN–13

INTRODUCTION

–

FOR ALL OF VEHICLES

(f)

SIDE AIRBAG ASSEMBLY

(1) Always store a removed or new side airbag assem-

bly with the airbag deployment direction facing up.

Storing the airbag assembly with the airbag deploy-

ment direction facing down could cause a serious

accident if the airbag inflates.

(2) Never measure the resistance of the airbag squib.

(This may cause the airbag to deploy, which is very

dangerous.)

(3) Grease should not be applied to the side airbag as-

sembly and the surface should not be cleaned with

detergents of any kind.

(4) Store the airbag assembly where the ambient tem-

perature remains below 93°C (200°F), without high

humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) under the

seat before starting work.

(6) When disposing of a vehicle or the side airbag as-

sembly alone, the airbag should be deployed using

an SST before disposal (See Pub. No. RM698E,

page RS–12).

Perform the operation in a safe place away from

electrical noise.

Example:

Correct

Wrong

B02129

Example:

B01546

AVENSIS/CORONA SUP (RM781E)

IN–14

INTRODUCTION

–

FOR ALL OF VEHICLES

(g) CURTAIN SHIELD AIRBAG ASSEMBLY

(1) Always store a removed or new curtain shield air-

bag assembly in a clear plastic bag, and keep it in

a safe place.

NOTICE:

Protection bag is not reuse.

CAUTION:

Never disassemble the curtain shield airbag assembly.

(2) Never measure the resistance of the airbag squib

(This may cause the airbag to deploy, which is very

dangerous.).

(3) Grease should not be applied to the curtain shield

airbag assembly and the surface should not be

cleaned with detergents of any kind.

(4) Store the airbag assembly where the ambient tem-

perature remains below 93°C (200°F), without high

humidity and away from electrical noise.

(5) When using electric welding, first disconnect the air-

bag connector (yellow color and 2 pins) into the

instrument panel before starting work.

(6) When disposing of a vehicle or the curtain shield air-

bag assembly alone, the airbag should be deployed

using an SST before disposal (See Pub. No.

RM698E, page RS–26).

Perform the operation in a safe place away from

electrical noise.

Example:

Clear Plastic Bag

Wrong

Correct

B08604

H11622 H12060

Example:

B08605

H12059R06952

AVENSIS/CORONA SUP (RM781E)

IN–15

INTRODUCTION

–

FOR ALL OF VEHICLES

(h) SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pre-

tensioner. (This may cause the pretensioner oper-

ates, which is very dangerous.)

(2) Oil or water should not be put on the front seat outer

belt and the front seat outer belt should not be

cleaned with detergents of any kind.

(3) Store the front seat outer belt where the ambient

temperature remains below 80°C (176°F), without

high humidity and away from electrical noise.

(4) When using electric welding, first disconnect the

connector (yellow color and 2 pins) installed at the

center pillar lower garnish before starting work.

(5) When disposing of a vehicle or a front seat outer

belt alone, the seat belt pretensioner should be acti-

vated before disposal (See Pub. No. RM599E,

page BO–153). Perform the operation in a safe

place away from electrical noise.

(i)

AIRBAG SENSOR ASSEMBLY

(1) Never reuse the airbag sensor assembly involved

in a collision when the SRS has deployed.

(2) The connectors to the airbag sensor assembly

should be connected or disconnected with the sen-

sor mounted on the floor. If the connectors are con-

nected or disconnected while the airbag sensor as-

sembly is not mounted to the floor, it could cause

undesired ignition of the supplemental restraint sys-

tem.

(3) Work must be started after 90 seconds from the

time the ignition switch is turned to the ”LOCK” posi-

tion and the negative (–) terminal cable is discon-

nected from the battery, even if only loosing the set

bolts of the airbag sensor assembly.

(j)

WIRE HARNESS AND CONNECTOR

The SRS wire harness is integrated with the instrument

panel wire harness and the cowl wire harness assembly

and floor wire harness assembly. The wires for the SRS

wire harness are encased in a yellow corrugated tube. All

the connectors for the system are also a standard yellow

color. If the SRS wire harness becomes disconnected or

the connector becomes broken due to an accident, etc.,

repair or replace it as shown on Pub. No. RM599E, page

RS–65.

AVENSIS/CORONA SUP (RM781E)

IN–16

2.

INTRODUCTION

–

FOR ALL OF VEHICLES

FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

CAUTION:

If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-

ard. To prevent this, observe the following precautions and explain them to your customer.

(a) Use only unleaded gasoline.

(b) Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20 minutes.

(c) Avoid spark jump test.

(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.

(2) While testing, never race the engine.

(d) Avoid prolonged engine compression measurement.

Engine compression tests must be done as rapidly as possible.

(e) Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra load on the converter.

(f)

Avoid coasting with ignition turned off and prolonged braking.

(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

3.

IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

For vehicles with mobile communication systems such as two–way radios and cellular telephones, observe

the following precautions.

(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle’s electronic

system.

(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-

hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on

the applicable component.

(3) Do not wind the antenna feeder together with the other wiring as much as possible, also avoid

running the antenna feeder parallel with other wire harnesses.

(4) Check that the antenna and feeder are correctly adjusted.

(5) Do not install powerful mobile communications system.

4.

FOR USING HAND–HELD TESTER

CAUTION:

Observe the following items for safety reasons:

S

Before using the hand–held tester, the hand–held tester’s operator manual should be read thor-

oughly.

Be sure to route all cables securely when driving with the hand–held tester connected to the

vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)

Two persons are required when test driving with the hand–held tester, one person to drive the

vehicle and the other person to operate the hand–held tester.

AVENSIS/CORONA SUP (RM781E)

IN–17

INTRODUCTION

–

FOR ALL OF VEHICLES

5.

FOR VEHICLES EQUIPPED WITH POWER WINDOW CONTROL SYSTEM

When the battery is disconnected or the power to the window regulator motor is cut, the power window con-

trol system does not operate. It is necessary to initialize the system in the following procedures. Otherwise

window cannot be operated normally.

(1) Close window to the highest position.

(2) Keep holding the switch for 5 seconds.

(3) Check that automatic operation works. If not, repeat the above procedures.

6.

FOR VEHICLES EQUIPPED WITH SLIDING ROOF SYSTEM

Sliding roof stop position might be required to be initialized when battery failures (such as battery disconnec-

tion, connector disconnection and the voltage drop) are detected while the system is in operation. This also

occurs when rotating the motor with the battery disconnected. Sliding roof initialization can be done by the

following procedures.

(1) Operate the roof up to the maximum tilt position.

(2) Release the switch, and push it again in the same direction. (After 10 seconds have elapsed,

initialization begins.)

(3) The roof starts automatic operation if holding the switch, completes full one cycle (tilt down, slide

open, slide close and tilt up) of travel. Do not release the switch until the roof stops.

(4) Check that the roof stops at the correct position.

AVENSIS/CORONA SUP (RM781E)

IN–18

INTRODUCTION

–

FOR ALL OF VEHICLES

7.

FOR VEHICLES EQUIPPED WITH TRACTION CON-

TROL (TRC) & VEHICLE STABILITY CONTROL (VSC)

SYSTEM

NOTICE:

S

When replacing the steering angle sensor or ECU, or

when adjusting the front wheel alignment or steering

wheel center point in accordance with the removing

and installing or replacing the suspension, axle, or

steering parts, make sure to perform the steering

angle sensor zero point calibration (See page

DI–171).

S

Do not remove or install the VSC related parts unless

necessary. Otherwise, there is a possibility that the

setting of the VSC to be affected.

When working on the VSC related operation, make

sure to check that the preparations before and after

work are completed according to the following

instruction.

S

When using a drum tester such as a speedometer tes-

ter or chassis dynamometer, etc., or jacking up the

front wheels and driving the wheels, always push in

the TRC & VSC cut (”VSC OFF”) switch and turn the

TRC & VSC system OFF.

(a) Press the VSC OFF switch.

(b) Check that the VSC OFF indicator light comes ON.

HINT:

The VSC OFF indicator light should be always OFF when the

engine is restarted.

F12737

B12536

F12737

(c) Begin measurements.

(d) Press the VSC OFF switch again to change the TRC &

VSC system to operational condition and check that the

VSC OFF indicator light goes off.

HINT:

S

The SLIP indicator light blinks when the TRC system is

operational.

S

The SLIP indicator light blinks and the VSC buzzer

sounds when the VSC system is operational.

AVENSIS/CORONA SUP (RM781E)

IN–19

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN00Z–45

GENERAL INFORMATION

A large number of ECU controlled systems are used in the AVENSIS/CORONA. In general, the ECU con-

trolled system is considered to be a very intricate system requiring a high level of technical knowledge and

expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, trouble-

shooting of these systems is not complex. If you have adequate understanding of the system and a basic

knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the

problem. This manual is designed through emphasis of the above standpoint to help service technicians

perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled sys-

tems:

The troubleshooting procedure and how to make use of it are described on the following pages.

System

Page

DI–1

1. AutomaticTransaxle(A246E)

2. AutomaticTransaxle(U240E)

DI–60

DI–127

DI–169

DI–255

3. Anti–Lock Brake System with Electronic Brake Force Distribution (EBD)

4. ABS with EBD & BA & TRC & VSC System

5. EngineImmobiliserSystem

FOR USING HAND–HELD TESTER

S

Before using the hand–held tester, the hand–held tester’s operator manual should be read thoroughly.

If the hand–held tester cannot communicate with ECU controlled systems when you have connected

the cable of the hand–held tester to DLC3, turned the ignition switch ON and operated the scan tool,

there is a problem on the vehicle side or tool side.

S

(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis

data link line (Busęline) or ECU power circuit of the vehicle.

(2) If communication is still not possible when the tool is connected to another vehicle, the problem

is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator’s

Manual.

AVENSIS/CORONA SUP (RM781E)

IN–20

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

IN06D–10

HOW TO PROCEED WITH TROUBLESHOOTING

Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro-

cedure is shown. Details are provided in DI section, showing the most effective methods for each circuit.

Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that

circuit.

Vehicle Brought to Workshop

1

Ask the customer about the conditions and the

environment when the problem occurred.

1

Customer Problem

Analysis

3

2

Symptom Confirmation

and Diagnostic Trouble

Code Check

Symptom Simulation

2, 3

Confirm the symptoms and the problem conditions,

and check the diagnostic trouble codes.

(When the problem symptoms do not appear

during confirmation, use the symptom simulation

method described later on.)

4

Diagnostic Trouble

Code Chart

5

Problem Symptoms Table

4, 5, 6

Check the results obtained in Step 2, then confirm

the inspection procedure for the system or the part

which should be checked using the diagnostic

trouble code chart or the problem symptoms table.

6

Circuit Inspection or Parts

Inspection

7

8

Check and repair the affected system or part in

accordance with the instructions in Step 6.

Repair

8

Confirmation Test

End

After completing repairs, confirm that the problem

has been eliminated.

(If the problem is not reproduced, perform the

confirmation test under the same conditions and

in the same environment as when it occurred for

the first time.)

AVENSIS/CORONA SUP (RM781E)

IN–21

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

1.

CUSTOMER PROBLEM ANALYSIS

In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be

cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it

is extremely important to ask the customer about the problem and the conditions at the time it occurred.

Important Point in the Problem Analysis:

The following 5 items are important points in the problem analysis. Past problems which are thought to be

unrelated and the repair history, etc. may also help in some cases, so as much information as possible should

be gathered and its relationship with the problem symptoms should be correctly ascertained for reference

in troubleshooting. A customer problem analysis table is provided in DI section for each system for your use.

Important Points in the Customer Problem Analysis

D What ––––– Vehicle model, system name

D When ––––– Date, time, occurrence frequency

D Where ––––– Road conditions

D Under what conditions? ––––– Running conditions, driving conditions, weather conditions

D How did it happen? ––––– Problem symptoms

(Sample) Supplemental restraint system check sheet.

CUSTOMER PROBLEM ANALYSIS CHECK

Inspector’s

Supplemental Restraint System Check Sheet

Name

RegistrationNo.

RegistrationYear

/

Customer’s Name

Frame No.

km

miles

OdometerReading

DateVehicleBroughtIn

/

Date Problem First Occurred

Weather

Other

Fine

Cloudy

Rainy

Snowy

Approx.

Temperature

Starting

Driving

Idling

Constantspeed

Other

VehicleOperation

[

Acceleration

Deceleration

]

AVENSIS/CORONA SUP (RM781E)

IN–22

2.

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK

The diagnostic system in the AVENSIS/CORONA fulfills various functions. The first function is the Diagnostic

Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU

memory at the time of occurrence, to be output by the technician during troubleshooting. Another function

is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly.

By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can

be performed effectively. Diagnostic functions are incorporated in the following systems in the AVENSIS/CO-

RONA.

Diagnostic Trouble

Code Check

Input Signal Check

(Sensor Check)

Diagnostic Test

System

Mode (Active Test)

f

1. AutomaticTransaxle(A246E)

2. AutomaticTransaxle(U240E)

f

(with check mode)

f

(with check mode)

3. Anti–Lock Brake System with Electronic Brake Force Distribution (EBD)

4. ABS with EBD & BA & TRC & VSC System

5. EngineImmobiliserSystem

f

In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-

nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,

it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic

trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes

should be checked before and after the symptom confirmation to determine the current conditions, as shown

in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting

for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent

to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble

code check.

DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE

Diagnostic Trouble

Code Check (Make a

note of and then clear)

Confirmation

of Symptoms

Diagnostic Trouble

Code Check

Problem Condition

Problem symptoms Same diagnostic

Diagnostic Trouble

Code Display

Problem is still occurring in the diagnostic

circuit

exist

trouble code is

displayed

Normal code is

displayed

The problem is still occurring in a place

other than in the diagnostic circuit

(The diagnostic trouble code displayed

first is either for a past problem or it is a

secondary problem)

No problem

symptoms exist

The problem occurred in the diagnostic

circuit in the past

The problem is still occurring in a place

other than in the diagnostic circuit

Problem symptoms Normal code is

Normal Code Display

exist

displayed

No problem

symptoms exist

Normal code is

displayed

The problem occurred in a place other

than in the diagnostic circuit in the past

AVENSIS/CORONA SUP (RM781E)

IN–23

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the

diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble

code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic

trouble code troubleshooting or to troubleshooting of problem symptoms.

Diagnostic trouble code check

Making a note of and clearing of the diagnostic trouble codes displayed

Symptom confirmation

No problem symptoms

Problem symptoms

exist

Simulation test using the symptom

simulation methods

Diagnostic trouble code check

D Diagnostic trouble code displayed

D Problem symptoms exist

D Normal code displayed

D Problem symptoms exist

D No problem symptoms exist

Troubleshooting of each

problem symptom

Troubleshooting of problem indicated

by diagnostic trouble code

System Normal

If a diagnostic trouble code was

displayed in the initial diagnostic

trouble code check, it indicates

that the trouble may have occurred

in a wire harness or connector in

that circuit in the past. Therefore,

check the wire harness and con-

nectors (See page IN–30).

AVENSIS/CORONA SUP (RM781E)

IN–24

3.

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

SYMPTOM SIMULATION

The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,

a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and

environment in which the problem occurred in the customer’s vehicle. No matter how much experience a

technician has, or how skilled he or she may be, if he or she proceeds to troubleshoot without confirming

the problem symptoms he or she will tend to overlook something important in the repair operation and make

a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs

when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving,

etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condi-

tion or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for prob-

lem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in

that the external causes are applied to the vehicle in a stopped condition.

Important Points in the Symptom Simulation Test:

In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area

or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-

toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation

test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-

toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible

causes of the symptom.

1

VIBRATION METHOD: When vibration seems to be the major cause.

CONNECTORS

Slightly shake the connector vertically and horizontally.

Shake Slightly

WIRE HARNESS

Slightly shake the wire harness vertically and horizontally.

The connector joint, fulcrum of the vibration, and body

through portion are the major areas to be checked thorough-

ly.

Swing Slightly

PARTS AND SENSOR

Vibrate Slightly

Apply slight vibration with a finger to the part of the sensor

considered to be the problem cause and check that the mal-

function occurs.

HINT:

Applying strong vibration to relays may result in open relays.

V07268

AVENSIS/CORONA SUP (RM781E)

IN–25

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

2

HEAT METHOD: When the problem seems to occur when the suspect area is heated.

Heat the component that is the likely cause of the malfunction

with a hair dryer or similar object. Check to see if the malfunction

occurs.

Malf unc-

tion

NOTICE:

(1)

Do not heat to more than 60 °C (140 °F). (Temperature

is limited not to damage the components.)

(2)

Do not apply heat directly to parts in the ECU.

When the malfunction seems to occur on a rainy day or in a

high–humidity condition.

3

WATER SPRINKLING METHOD:

Sprinkle water onto the vehicle and check to see if the malfunc-

tion occurs.

NOTICE:

(1) Never sprinkle water directly into the engine compart-

ment, but indirectly change the temperature and hu-

midity by applying water spray onto the radiator front

surface.

(2) Never apply water directly onto the electronic compo-

nents.

HINT:

If a vehicle is subject to water leakage, the leaked water may

contaminate the ECU. When testing a vehicle with a water leak-

age problem, special caution must be taken.

4

OTHER: When a malfunction seems to occur when electrical load is excessive.

Turn on all electrical loads including the heater blower, head

lights, rear window defogger, etc. and check to see if the mal-

function occurs.

ON

B02389

B02390

AVENSIS/CORONA SUP (RM781E)

IN–26

4.

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

DIAGNOSTIC TROUBLE CODE CHART

The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot-

ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble-

shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the

diagnostic trouble codes displayed. The Supplemental Restraint System diagnostic trouble code chart is

shown below as an example.

D DTC No.

Indicates the diagnostic trouble code.

Page or Instructions

D

Trouble Area

Indicates the suspect area of the

problem.

Indicates the page where the inspection procedure

for each circuit is to be found, or gives instructions

for checking and repairs.

D

Detection Item

Indicates the system of the problem or

contents of the problem.

DIAGNOSTIC TROUBLE CODE CHART

If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table

below. (Proceed to the page given for that circuit).

DTC No.

SRS

WarmingLight

DetectionItem

TroubleArea

(Seepage)

Short in D squib circuit (to ground)

D Steering wheel pad (squib)

11

D Spiral cable

ON

(DI–165)

D Airbag sensor assembly

D Wire harness

Short in D squib circuit (to B))

Short in D squib circuit

D Steering wheel pad (squib)

D Spiral cable

12

ON

(DI–170)

D Airbag sensor assembly

D Wire harness

D Steering wheel pad (squib)

D Spiral cable

13

(DI–174)

D Airbag sensor assembly

D Wire harness

Open in D squib circuit

D Steering wheel pad (squib)

D Spiral cable

14

ON

D Airbag sensor assembly

(DI–178)

D Wire harness

15

Front airbag sensor assembly (RH)

malfunction

D Front airbag sensor assembly (RH)

D Wire harness

(DI–178)

16

Front airbag sensor assembly (LH)

malfunction

D Front airbag sensor assembly (LH)

ON

D Wire harness

airbag sensor assembly malfunction

Airbag sensor assembly

ON

Short in P squib circuit (to ground)

D Front passenger airbag sensor assembly (squib)

D Airbag sensor assembly

AVENSIS/CORONA SUP (RM781E)

IN–27

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

5.

PROBLEM SYMPTOMS TABLE

The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to

troubleshoot the problem when a ”Normal” code is displayed in the diagnostic trouble code check but the

problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts

should be checked.

HINT:

When the problem is not detected by the diagnostic system even though the problem symptom is present,

it is considered that the problem is occurring outside the detection range of the diagnostic system, or that

the problem is occurring in a system other than the diagnostic system.

Page

D

Indicates the page where the flow chart for each circuit

is located.

D

Circuit Inspection, Inspection Order

Indicates the circuit which needs to be checked for each problem

symptom. Check in the order indicated by the numbers.

D

Circuit or Part Name

Indicates the circuit or part which needs to be checked.

D Problem Symptom

PROBLEM SYMPTOMS TABLE

Proceed with troubleshooting of each circuit in the table below.

See page

DI–288

Symptom

Suspect Area

D WiththeignitionswitchintheACCorONposition,theSRSwarning

lightsometimes lights up after approx. 6 seconds have elapsed.

D SRS warning light is always lit up even when ignition switch is in

the LOCK position

D SRS warning light circuit

(Always lights up when ignition switch is in

LOCKposition.)

D SRS warning light circuit

D WiththeignitionswitchintheACCorONposition,theSRSwarning

DI–290

DI–294

(Dose not light up when ignition switch is turned to

ACC or ON.)

lightdoes not light up.

D DTC is not displayed.

D

SRS warning light is always lit up at the time of DTC check

D Tc terminal circuit

procedure.

D DTC is displayed without Tc and E1 terminal connection.

AVENSIS/CORONA SUP (RM781E)

IN–28

6.

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

CIRCUIT INSPECTION

How to read and use each page is shown below.

D Diagnostic Trouble Code No. and Detection Item

D

Circuit Description

The major role and operation, etc. of the circuit

and its component parts are explained.

DTC

13

Short in D Squib Circuit

CIRCUIT DESCRIPTION

The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad.

It causes the airbag to deploy when the airbag deployment conditions are satisfied.

For details of the function of each components,see OPERATION on page RS–2.

DTC 13 is recorded when a short is detected in the D squib circuit.

DTC Detecting Condition

Trouble Area

DTC No.

SShort circuit between D) wire harness and D* wire harness of squib SSteering wheel pad (D squib)

SD squib malfunction

SSpiral cable

SAirbag sensor assembly

SWire harness

13

SSpiral cable malfunction

SAirbag sensor assembly malfunction

D

Indicates the diagnostic trouble code, diagnostic

trouble code set parameter and suspect area of

the problem.

WIRING DIAGRAM

D

Wiring Diagram

This shows a wiring diagram of the circuit.

Use this diagram together with ELECTRICAL

WIRING DIAGRAM to thoroughly understand the

circuit.

Airbag Sensor

Assembly

Wire colors are indicated by an alphabetical code.

B = Black, L = Blue, R = Red, BR = Brown,

LG = Light Green, V = Violet, G = Green,

O = Orange, W = White, GR = Gray, P = Pink,

Y = Yellow

1

G–R

G–Y

7

6

+

A15

D

Spiral

Cable

D Squib

–

A15

D

2

The first letter indicates the basic wire color and

the second letter indicates the color of the stripe.

R16015

B02407

AVENSIS/CORONA SUP (RM781E)

IN–29

INTRODUCTION

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HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

D Indicates the position of the ignition switch during the check. D Inspection Procedure

Use the inspection procedure to determine

if the circuit is normal or abnormal, and if it

is abnormal, use it to determine whether the

problemis located in the sensors, actuators,

wire harness or ECU.

ON

LOCK

Ignition Switch ON

IgnitionSwitch LOCK (OFF)

START

ACC

Ignition Switch ACC

Ignition Switch START

INSPECTION PROCEDURE

2

Check voltage at IG2 and ACC of airbag sensor assembly.

PREPARATION:

Turn ignition switch ON.

CHECK:

ON

AirbagSensor Assembly

Measure voltage between terminals IG2 and ACC of

airbag sensor assembly and body ground.

ACC

(+)

IG2

(–)

OK:

AB0119

W02766

Voltage: Below 16V

H00041

Check battery and charging system.

(See charging system section)

NG

OK

D Indicates the place to check the voltage or resistance.

D Indicates the connector position to be checked, from the front or back side.

Wire Harness

Check from the connector front side. (without harness)

In this case, care must be taken not to bend the terminals.

Check from the connector back side.

(with harness)

D Indicates the condition of the connector of ECU during the check.

KNK

E6 Connector

Connector being checked is disconnected.

Connector being checked is connected.

B00691

B00972

AVENSIS/CORONA SUP (RM781E)

IN–30

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

IN011–38

HOW TO USE THE DIAGNOSTIC

CHART AND INSPECTION

PROCEDURE

1.

CONNECTOR CONNECTION AND TERMINAL IN-

SPECTION

S

For troubleshooting, diagnostic trouble code charts or

problem symptom charts are provided for each circuit with

detailed inspection procedures on the following pages.

When all the component parts, wire harnesses and con-

nectors of each circuit except the ECU are found to be

normal in troubleshooting, then it is determined that the

problem is in the ECU. Accordingly, if diagnosis is per-

formed without the problem symptoms occurring, refer to

Step 8 to replace the ECU. So always confirm that the

problem symptoms are occurring, or proceed with inspec-

tion while using the symptom simulation method.

The instructions ”Check wire harness and connector” and

”Check and replace ECU” which appear in the inspection

procedure, are common and applicable to all diagnostic

trouble codes. Follow the procedure outlined below

whenever these instructions appear.

FI0046

FI0047

FI0048

S

OPEN CIRCUIT:

This could be due to a disconnected wire harness, faulty con-

tact in the connector, and a connector terminal pulled out, etc.

HINT:

S

It is rarely the case that a wire is broken in the middle of

it. Most cases occur at the connector. In particular, care-

fully check the connectors of sensors and actuators

Faulty contact could be due to rusting of the connector

terminals, to foreign materials entering terminals or a de-

formation of connector terminals. Simply disconnecting

and reconnecting the connectors once changes the

condition of the connection and may result in a return to

normal operation. Therefore, in troubleshooting, if no ab-

normality is found in the wire harness and connector

check, but the problem disappears after the check, then

the cause is considered to be in the wire harness or con-

nectors.

S

SHORT CIRCUIT:

This could be due to a contact between wire harness and the

body ground or to a short circuit occurred inside the switch, etc.

HINT:

When there is a short between the wire harness and body

ground, check thoroughly whether the wire harness is caught

in the body or is clamped properly.

AVENSIS/CORONA SUP (RM781E)

IN–31

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

2.

CONNECTOR HANDLING

When inserting tester probes into a connector, insert them from

the rear of the connector. When necessary, use mini test leads.

For water resistant connectors which cannot be accessed from

behind, take good care not to deform the connector terminals.

FI7187

IN0379

IN0378

IN0380

3.

CONTINUITY CHECK (OPEN CIRCUIT CHECK)

Sensor Side

ECU Side

(a) Disconnect the connectors at both ECU and sensor

sides.

(b) Measure the resistance between the applicable terminals

of the connectors.

Resistance: 1 Ω or less

HINT:

Measure the resistance while lightly shaking the wire harness

vertically and horizontally.

ECU Side

Sensor Side

4.

RESISTANCE CHECK (SHORT CIRCUIT CHECK)

ECU Side

(a) Disconnect the connectors on both ends.

(b) Measure the resistance between the applicable terminals

of the connectors and body ground. Be sure to carry out

this check on the connectors on both ends.

Resistance: 1 MΩ or higher

Sensor Side

HINT:

Measure the resistance while lightly shaking the wire harness

vertically and horizontally.

5.

VISUAL CHECK AND CONTACT PRESSURE CHECK

(a) Disconnect the connectors at both ends.

(b) Check for rust or foreign material, etc. in the terminals of

the connectors.

(c) Check crimped portions for looseness or damage and

check that the terminals are secured in lock portion.

HINT:

Pull Lightly

Looseness of Crimping

The terminals should not come out when pulled lightly from the

back.

IN0381

AVENSIS/CORONA SUP (RM781E)

IN–32

INTRODUCTION

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HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

(d) Prepare a test male terminal and insert it in the female ter-

minal, then pull it out.

NOTICE:

When testing a gold–plated female terminal, always use a

gold–plated male terminal.

HINT:

When the test terminal is pulled out more easily than others,

there may be poor contact in that section.

6.

CHECK OPEN CIRCUIT

Fig. 1

ECU

For the open circuit in the wire harness in Fig. 1, perform ”(a)

Continuity Check” or ”(b) Voltage Check” to locate the section.

C

OPEN

B

A

1

2

Sensor

1

2

1

2

1

2

Z17004

(a) Check the continuity.

Fig. 2

(1) Disconnect connectors ”A” and ”C” and measure

the resistance between them.

ECU

In the case of Fig. 2:

A

C

1

2

B

Between terminal 1 of connector ”A” and terminal 1

of connector ”C” → No continuity (open)

Between terminal 2 of connector ”A” and terminal 2

of connector ”C” → Continuity

Sensor

1

2

1

2

Therefore, it is found out that there is an open circuit

between terminal 1 of connector ”A” and terminal 1

of connector ”C”.

Z17005

Fig. 3

(2) Disconnect connector ”B” and measure the resis-

tance between the connectors.

ECU

In the case of Fig. 3:

Between terminal 1 of connector ”A” and terminal 1

of connector ”B1” → Continuity

Between terminal 1 of connector ”B2” and terminal

1 of connector ”C” → No continuity (open)

Therefore, it is found out that there is an open circuit

between terminal 1 of connector ”B2” and terminal

1 of connector ”C”.

Sensor

B2

C

1

2

B1

A

1

2

1

2

1

2

B04722

AVENSIS/CORONA SUP (RM781E)

IN–33

INTRODUCTION

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HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

(b) Check the voltage.

Fig. 4

In a circuit in which voltage is applied (to the ECU connec-

tor terminal), an open circuit can be checked for by con-

ducting a voltage check.

5V

A

0V

C

Sensor

As shown in Fig. 4, with each connector still con-

nected, measure the voltage between body ground

and terminal 1 of connector ”A” at the ECU 5V out-

put terminal, terminal 1 of connector ”B”, and termi-

nal 1 of connector ”C”, in that order.

5V

B

5V

1

2

Z17007

If the results are:

5V: Between Terminal 1 of connector ”A” and Body Ground

5V: Between Terminal 1 of connector ”B” and Body Ground

0V: Between Terminal 1 of connector ”C” and Body Ground

Then it is found out that there is an open circuit in the wire har-

ness between terminal 1 of ”B” and terminal 1 of ”C”.

7.

CHECK SHORT CIRCUIT

Fig. 5

If the wire harness is ground shorted as in Fig. 5, locate the sec-

tion by conducting a ”continuity check with ground”.

C

1

2

SHORT

B

1

2

A

1

2

Z17008

Check the continuity with ground.

Fig. 6

(1) Disconnect connectors ”A” and ”C” and measure

the resistance between terminal 1 and 2 of connec-

tor ”A” and body ground.

ECU

B

C

1

2

A

1

2

In the case of Fig. 6:

Between terminal 1 of connector ”A” and body

ground → Continuity (short)

Sensor

1

2

Between terminal 2 of connector ”A” and body

ground → No continuity

Z17009

Therefore, it is found out that there is a short circuit

between terminal 1 of connector ”A” and terminal 1

of connector ”C”.

AVENSIS/CORONA SUP (RM781E)

IN–34

INTRODUCTION

–

HOW TO TROUBLESHOOTECU CONTROLLED

SYSTEMS

(2) Disconnect connector ”B” and measure the resis-

tance between terminal 1 of connector ”A” and body

ground, and terminal 1 of connector ”B2” and body

ground.

Fig. 7

ECU

In the case of Fig. 7:

Between terminal 1 of connector ”A” and body

ground → No continuity

B2

1

2

C

1

2

B1

1

2

A

1

2

Sensor

Between terminal 1 of connector ”B2” and body

ground → Continuity (short)

Z17808

Therefore, it is found out that there is a short circuit

between terminal 1 of connector ”B2” and terminal

1 of connector ”C”.

8.

CHECK AND REPLACE ECU

First check the ECU ground circuit. If it is faulty, repair it. If it is

normal, the ECU could be faulty, so replace the ECU with a nor-

mal functioning one and check that the symptoms appear.

(1) Measure the resistance between the ECU ground

terminal and the body ground.

Resistance: 1 Ω or less

Example

Ground

IN0383

(2) Disconnect the ECU connector, check the ground

terminals on the ECU side and the wire harness

side for bend and check the contact pressure.

ECU Side

Ground

W/H Side

Ground

IN0384

AVENSIS/CORONA SUP (RM781E)

IN–35

INTRODUCTION

–

TERMS

IN044–12

ABBREVIATIONS USED IN THIS MANUAL

Abbreviations

Meaning

ABS

A/C

Anti–LockBrake System

AirConditioner

AC

AlternatingCurrent

Accessory

ACC

ACIS

ACSD

A.D.D.

AHC

ALR

Acoustic Control Induction System

Automatic Cold Start Device

AutomaticDisconnectingDifferential

Active Height Control Suspension

AutomaticLockingRetractor

Alternator

ALT

AMP

ANT

APPROX.

A/T

Amplifier

Antenna

Approximately

AutomaticTransmission (Transaxle)

AutomaticTransmissionFluid

Automatic

ATF

AUTO

BACS

BAT

BoostAltitudeCompensationSystem

Battery

B/L

Bi–Level

BVSV

CB

BimetallicVacuum Switching Valve

Circuit Breaker

CD

Compact Disc

CH

Channel

CKD

COMB.

CPE

CRS

CTR

DC

Complete Knock Down

Combination

Coupe

Child Restraint System

Center

Direct Current

DIFF.

DIFF. LOCK

DLC

DSP

DTC

ECT

ECU

EDU

EFI

Differential

DifferentialLock

Data Link Connector

Digital Signal Processor

Diagnostic TroubleCode

Electronic Control Transmission

Electronic Control Unit

Electronic Driving Unit

ElectronicFuelInjection

Engine

E/G

EGR

ELR

Exhaust Gas Recirculation

Emergency Locking Retractor

Electronic Vacuum Regulating Valve

E–VRV

AVENSIS/CORONA SUP (RM781E)

IN–36

INTRODUCTION

–

TERMS

FF

Front–EngineFront–Wheel–Drive

Formed In Place Gasket

FusibleLink

FIPG

FL

Fr

Front

FR

Front–EngineRear–Wheel–Drive

Front–Wheel–Drive

Ground

FWD

GND

H/B

HI

Hatchback

High

HID

HT

High Intensity Discharge (Head Lamp)

Hard Top

HWS

IAC

IFS

HeatedWindshieldSystem

Idle Air Control

IndependentFrontSuspension

Ignition

IG

INT

Intermittent

I/P

InstrumentPanel

IRS

J/B

IndependentRearSuspension

Junction Block

J/C

JunctionConnector

Local Area Network

Liftback

LAN

LB

LCD

LED

LH

Liquid Crystal Display

LightEmittingDiode

Left–Hand

LHD

LO

Left–HandDrive

Low

LSD

LSP & PV

LSPV

MAP

MAX.

MIC

MIL

MIN.

MP

Limited Slip Differential

Load Sensing Proportioning And Bypass Valve

Load Sensing Proportioning Valve

ManifoldAbsolutePressure

Maximum

Microphone

MalfunctionIndicatorLamp

Minimum

Multipurpose

MPI

MPX

M/T

N

MultipointElectronicFuelInjection

MultiplexCommunicationSystem

ManualTransmission

Neutral

No.

Number

O2S

O/D

OPT

P & BV

Oxygen Sensor

Overdrive

Option

Proportioning And Bypass Valve

Power Control System

PCS

AVENSIS/CORONA SUP (RM781E)

IN–37

INTRODUCTION

–

TERMS

PKB

PPS

PS

Parking Brake

Progressive Power Steering

PowerSteering

PTO

RAM

R/B

Power Take–Off

Random Access Memory

Relay Block

RBS

R/F

Recirculating Ball TypeSteering

Reinforcement

RFS

RH

Rigid Front Suspension

Right–Hand

RHD

RLY

ROM

Rr

Right–HandDrive

Relay

Read Only Memory

Rear

RR

Rear–EngineRear–WheelDrive

Rigid Rear Suspension

Rear–WheelDrive

Sedan

RRS

RWD

SDN

SEN

SICS

SPEC

SRS

SSM

SST

STD

SW

Sensor

Starting Injection Control System

Specification

SupplementalRestraintSystem

Special Service Materials

Special Service Tools

Standard

Switch

SYS

T/A

System

Transaxle

TACH

TDC

TEMP.

TEMS

TFT

T/M

Tachometer

Top Dead Center

Temperature

TOYOTAElectronicModulatedSuspension

ToyotaFree–Tronic

Transmission

TMC

TRC

U/D

TOYOTA Motor Corporation

Traction Control System

Underdrive

VENT

VIN

Ventilator

VehicleIdentificationNumber

VehicleStabilityControl

Vacuum Switching Valve

With

VSC

VSV

w/

WGN

W/H

w/o

Wagon

Wire Harness

Without

1st

First

AVENSIS/CORONA SUP (RM781E)

IN–38

INTRODUCTION

–

TERMS

2nd

Second

2WD

4WD

Two Wheel Drive Vehicle (4x2)

Four Wheel Drive Vehicle (4x4)

AVENSIS/CORONA SUP (RM781E)

INTRODUCTION for Your Toyota Avensis 4 Door First Generation (1997-2003)

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