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TOYOTA
REPAIR MANUAL SUPPLEMENT
FOR CHASSIS & BODY
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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 supple­
ment, refer to the following manuals.
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
Manual Name Pub. No.
• YARIS/ECHO Chassis and Body Repair Manual RM685E
• YARIS/ECHO Chassis and Body Repair Manual Supplement (Aug., 1999) RM737E
• YARIS/ECHO Chassis and Body Repair Manual Supplement (Jan., 2001) RM838E
• 1SZ-FE Engine Repair Manual RM686E
• 1 SZ-FE Engine Repair Manual Supplement RM839E
• 1NZ-FE, 2NZ-FE Engine Repair Manual RM749E
• 1 ND—TV Engine Repair Manual RM920E
• U340E, U341E Automatic Transaxle Repair Manual (Aug., 1999) RM735U
• U440E, U441E Automatic Transaxle Repair Manual (Jan., 1999) RM689E
TOYOTA MOTOR CORPORATION
©2003 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be repro­
duced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: Aug. 1,2001 01-010801-00
Third Printing: Sep. 8, 2003 03-030908-00-3
https://autocarmanual.com
Download Full Workshop..
manual at Autocarmanual.com
Free Preview
CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that non-specialized or uncertified technicians perform repair or service only using this manu­
al or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customer’s vehicle.
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 spe­
cified 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
part. Do 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
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
CLUTCH
C153 MANUAL TRANSAXLE
SUSPENSION AND AXLE
BRAKE |
STEERING !
BODY ELECTRICAL |
AIR CONDITIONING |
ALPHABETICAL INDEX |
IN
PP
SS
DI
CL
MX
SA
BR
SR'
BE
AC
ID
INTRODUCTION
!
HOW TO USE THIS MANUAL................................. IN-1
GENERAL INFORMATION.................................. IN-1
IDENTIFICATION INFORMATION........................... IN-3
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER............................... IN-3
REPAIR INSTRUCTIONS......................................... IN-5
GENERAL INFORMATION................................... IN-5
VEHICLE LIFT AND
SUPPORT LOCATIONS.................................... IN-9
FOR ALL OF VEHICLES.................................... IN-13
PRECAUTION.................................................. IN-13
HOW TO TROUBLESHOOT
ECU CONTROLLED SYSTEMS.......................... IN-21
GENERAL INFORMATION................................... IN-21
HOW TO PROCEED WITH
TROUBLESHOOTING..................................... IN-22
HOW TO USE THE DIAGNOSTIC CHART
AND INSPECTION PROCEDURE................... IN-32
TERMS..................................................................... IN-37
ABBREVIATIONS USED IN THIS MANUAL .... IN-37
IN—1
INTRODUCTION - HOW TO USE THIS MANUAL
HOW TO USE THIS MANUAL
GENERAL INFORMATION
W00U-31
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
IN
2. GENERAL DESCRIPTION
At the beginning of each section, a General Description is given that pertains to all repair operations con­
tained 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 this before performing troubleshooting.
4. PREPARATION
Filler Cap
Float Clevis Pin
Cylinder
N-m (kgf-cm, ft-lbf) : Specified torque
♦ Non-reusable part N1708C
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:
IN-2
______________________________________ INTRODUCTION - HOW TO U SE TH IS .MAN UAL
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:
> Illustration:. c |
what to do and where
Task heading: 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. - I • | ”
SST 09350-30020 (09350-06120) ‘ 'T*
XX
Set part No. Component part No. . : , J ., .=
Dotailccpcxt: how to do task *- - • ■
(b) Measure the stroke applying and releasing the compressed s y ■
air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57—114 psi) as shown
in the illustration.
Piston stroke: 1.40—1.70 mm (0.0551 — 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:
• CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
• 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)
INTRODUCTION IDENTIFICATION INFORMATION
IN-3
IDENTIFICATION INFORMATIONH04P-21
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped in the engine
compartment as shown in the illustration. This number has also
been stamped on the manufacturer’s plate, as shown in the il­
lustration.
A: Vehicle Identification Number
B: Manufacturer’s Plate
Hatchback model:
IN
B15729
IN—4
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
INTRODUCTION - 1D£NTLELGAILQK INFQRMAIIQN.
INTRODUCTION REPAIR INSTRUCTIONS
IN-5
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a)
(b)
(c)
(d)
(e)
Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
During disassembly, keep parts in the appropriate order
to facilitate reassembly.
Installation and removal of battery terminal:
(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 cable.
(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.
Check hose and wiring connectors to make sure that they
are connected securely and correctly.
Non-reusable parts
(1) Always replace cotter pins, gaskets, O-rings, oil
seals, etc. with new ones.
(2) Non-reusable parts are indicated in the component
illustrations by the syrtftfol.
(0 Precoated parts
Precoated parts are bolts, 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.
IN-6
INTRODUCTION - REPAIR INSTRUCTIONS
(3) Precoated parts are indicated in the component il­
lustrations by the syrtfool.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(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.
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.
Illustration Symbol Part Name Abbreviation
BE5594 IN0365
FUSE FUSE
BE5695 IN0366
MEDIUM CURRENT FUSE M-FUSE
BE5596 INO367
HIGH CURRENT FUSE H-FUSE
IN0367
FUSIBLE LINK FL
BE5698 ......TN036S
CIRCUIT BREAKER CB
V00076
INTRODUCTION REPAIR INSTRUCTIONS
IN-7
(k)
(I)
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—9).
Cancel the parking brake on the level place and
shift the transmission in Neutral (or N range).
When jacking up the front wheels of the vehicle, at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle, at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
• After the vehicle is jacked up, be sure to support it
on rigid racks. It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
Observe the following precautions to avoid damage to the
following parts:
(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.
(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.
(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.
(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.
IN—8
INTRODUCTION - REPAIR INSTRUCTIONS
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.
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.
INTRODUCTION - REPAIR INSTRUCTIONS
IN-9
VEHICLE LIFT AND SUPPORT LOCATIONS
INOFP-Ot
p
JACK POSITION ------------------------------------------
Front Front suspension member
Rear Lower Back Outer Panel (Protrusion)
CAUTION : When jacking-up the front and rear, make sure the vehicle is
not carrying any extra weight.
PANTOGRAPH JACK POSITION------------
SUPPORT POSITION
Safety stand and swing arm type lift
o
B02414
iN-10
Sedan model: do not Jack up
Do not jack up
JACK POSITION -------------------------------------------
Front Front suspension member
Rear Lower Back Outer Panel (Protrusion)
CAUTION : When jacking-up the front and rear, make sure the vehicle is
not carrying any extra weight.
PANTOGRAPH JACK POSITION-------------
SUPPORT POSITION
Safety stand and swing arm type lift
B09701
INTRODUCTION REPAIR INSTRUCTIONS
IN—11
Hatchback model:
Plate type lift
HINT:
Right and left set position Place the vehicle over the center of the lift.
Front and rear set position • When using attachments, place the one for
front side vertically and the one for rear side
horizontally to the vehicle.
• Align the cushion gum ends of the plate
with the attachment lower ends (A, C).
• Align the attachment upper end (B) with the
rocker flange rear side notch.
Attachment dimensions
3 B02415
IN—12
INTRODUCTION - REPAIR INSTRUCTIONS
HINT:
Right and left set position Place the vehicle over the center of the lift.
Front and rear set position • When using attachments, place the one for
front side vertically and the one for rear side
horizontally to the vehicle.
• Align the cushion gum ends of the plate
with the attachment lower ends (A, C).
• Align the attachment upper end (B) with the
rocker flange rear side notch.
Attachment dimensions
p. B09700
INTRODUCTION FOR ALL OF VEHICLES
IN—13
FOR ALL OF VEHICLES
PRECAUTION
IN0FQ-03
1.
(a)
(b)
FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER (See Pub. No. RM685E
on page RS-1)
The YARIS/ECHO is equipped with an SRS (Supplemen­
tal Restraint System), such as the driver airbag, front pas­
senger airbag assembly, side airbag assembly 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.
GENERAL NOTICE
(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. RM838E
on page DI-159).
(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 anoth­
er battery.
IN—14
INTRODUCTION - f OF* ALL OF VEHICLE.
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad, front pas­
senger airbag assembly, side airbag assembly, air­
bag sensor assembly, front airbag sensor, side air­
bag sensor assembly and seat belt pretensioner
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, steering wheel pad, front passenger airbag
assembly, side airbag assembly, airbag sensor as­
sembly, front airbag sensor, side airbag sensor as­
sembly or seat belt pretensioner.
(7) If the airbag sensor assembly, steering wheel pad,
front passenger airbag assembly, side airbag as­
sembly, airbag sensor assembly, front airbag sen­
sor, side airbag sensor assembly or seat belt pre­
tensioner has been dropped, or if there are cracks,
dents or other defects in the case, bracket or con­
nector, replace them with new ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad, front passenger airbag assem­
bly, side airbag assembly, airbag sensor assembly,
front airbag sensor, side airbag sensor assembly or
seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kD/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. RM838E on page DI—159).
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 See Pub. No. RM838E on page SR-9 of this
manual concerning correct steering wheel installation.
INTRODUCTION FOR ALL OF VEHICLES
IN-15
(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 de­
ploys 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. RM685E on
page RS-14).
Carry out the operation in a safe place away from
electrical noise.
IN—16
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 deploys.
(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 front passenger
airbag assembly alone, the airbag should be
deployed using an SST before disposal (See Pub.
No. RM685E on page RS-27).
Perform the operation in a safe place away from
electrical noise.
Example:
Correct
o
N
Wrong
X
B02420
IN-17
INTRODUCTION - FOR ALL OE 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 deploys.
(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. RM737E
RS-17).
Perform the operation in a safe place away from
electrical noise.
Example:
X
N21642
IN—18
INTRODUCTION - FOR ALLCO/EHICLES
(g) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pre­
tensioner. (This may cause the seat belt pretension­
er to activate, which is very dangerous.)
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner in another
vehicle.
(4) Store the seat belt pretensioner where the ambient
temperature remains below 80°C (176°F) and
away from electrical noise without high humidity.
(5) When using electric welding, first disconnect the
connector (yellow color and 2 pins) before starting
work.
(6) When disposing of a vehicle or the seat belt preten­
sioner alone, the seat belt pretensioner should be
activated before disposal (See Pub. No. RM685E
on page BO-130 and See Pub. No. RM737E on
page BO-65).
Perform the operation in a safe place away from
electrical noise.
(7) The seat belt pretensioner is hot after activation, so
let it cool down sufficiently before the disposal.
However never apply water to the seat belt preten­
sioner.
(8) 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.
INTRODUCTION FOR ALL QF VEHICLES
IN-19
(h) 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.
(i) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly. All the connectors in the
system are a standard yellow color. If the SRS wire har­
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it as
shown on page (See Pub. No. RM737E on page RS-47).
2. 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.
(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) Avoid winding the antenna feeder together with other wiring as much as possible, and 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.
IN-20
INTRODUCTION - FOR ALL OF VEHICLES
4. FOR USING HAND-HELD TESTER
CAUTION:
Observe the following items for safety reasons:
• 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.
5. FOR VEHICLES EQUIPPED WITH TOYOTA FREE-TRONIC
CAUTION:
Do not operate the throttle link when the shift lever is in any position other than neutral while the en­
gine is rotating. The vehicle might start suddenly.
6. FOR VEHICLES EQUIPPED WITH TOYOTA STOP AND GO SYSTEM
NOTICE:
When disconnecting the negative (-) terminal cable from the battery, after completing work, repeat
depressing and releasing the clutch pedal in a full degree 10 times or more.
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Toyota Yaris service manual Free.pdf Toyota Yaris Service manual

  • 1. TOYOTA REPAIR MANUAL SUPPLEMENT FOR CHASSIS & BODY Autocarmanual.com
  • 2. https://autocarmanual.com Free Preview Download Full Workshop manual at Autocarmanual.com
  • 3. 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 supple­ ment, refer to the following manuals. All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. Manual Name Pub. No. • YARIS/ECHO Chassis and Body Repair Manual RM685E • YARIS/ECHO Chassis and Body Repair Manual Supplement (Aug., 1999) RM737E • YARIS/ECHO Chassis and Body Repair Manual Supplement (Jan., 2001) RM838E • 1SZ-FE Engine Repair Manual RM686E • 1 SZ-FE Engine Repair Manual Supplement RM839E • 1NZ-FE, 2NZ-FE Engine Repair Manual RM749E • 1 ND—TV Engine Repair Manual RM920E • U340E, U341E Automatic Transaxle Repair Manual (Aug., 1999) RM735U • U440E, U441E Automatic Transaxle Repair Manual (Jan., 1999) RM689E TOYOTA MOTOR CORPORATION ©2003 TOYOTA MOTOR CORPORATION All rights reserved. This book may not be repro­ duced or copied, in whole or in part, without the written permission of Toyota Motor Corporation. First Printing: Aug. 1,2001 01-010801-00 Third Printing: Sep. 8, 2003 03-030908-00-3
  • 5. CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non-specialized or uncertified technicians perform repair or service only using this manu­ al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle. 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 spe­ cified 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 part. Do 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.
  • 6.
  • 7. INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS CLUTCH C153 MANUAL TRANSAXLE SUSPENSION AND AXLE BRAKE | STEERING ! BODY ELECTRICAL | AIR CONDITIONING | ALPHABETICAL INDEX | IN PP SS DI CL MX SA BR SR' BE AC ID
  • 8.
  • 9. INTRODUCTION ! HOW TO USE THIS MANUAL................................. IN-1 GENERAL INFORMATION.................................. IN-1 IDENTIFICATION INFORMATION........................... IN-3 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER............................... IN-3 REPAIR INSTRUCTIONS......................................... IN-5 GENERAL INFORMATION................................... IN-5 VEHICLE LIFT AND SUPPORT LOCATIONS.................................... IN-9 FOR ALL OF VEHICLES.................................... IN-13 PRECAUTION.................................................. IN-13 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS.......................... IN-21 GENERAL INFORMATION................................... IN-21 HOW TO PROCEED WITH TROUBLESHOOTING..................................... IN-22 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE................... IN-32 TERMS..................................................................... IN-37 ABBREVIATIONS USED IN THIS MANUAL .... IN-37
  • 10.
  • 11. IN—1 INTRODUCTION - HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL GENERAL INFORMATION W00U-31 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 IN 2. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations con­ tained 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 this before performing troubleshooting. 4. PREPARATION Filler Cap Float Clevis Pin Cylinder N-m (kgf-cm, ft-lbf) : Specified torque ♦ Non-reusable part N1708C 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:
  • 12. IN-2 ______________________________________ INTRODUCTION - HOW TO U SE TH IS .MAN UAL 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: > Illustration:. c | what to do and where Task heading: 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. - I • | ” SST 09350-30020 (09350-06120) ‘ 'T* XX Set part No. Component part No. . : , J ., .= Dotailccpcxt: how to do task *- - • ■ (b) Measure the stroke applying and releasing the compressed s y ■ air (392 — 785 kPa, 4 — 8 kgf/cm2 or 57—114 psi) as shown in the illustration. Piston stroke: 1.40—1.70 mm (0.0551 — 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: • CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. • 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)
  • 13. INTRODUCTION IDENTIFICATION INFORMATION IN-3 IDENTIFICATION INFORMATIONH04P-21 VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped in the engine compartment as shown in the illustration. This number has also been stamped on the manufacturer’s plate, as shown in the il­ lustration. A: Vehicle Identification Number B: Manufacturer’s Plate Hatchback model: IN B15729
  • 14. IN—4 2. ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. INTRODUCTION - 1D£NTLELGAILQK INFQRMAIIQN.
  • 15. INTRODUCTION REPAIR INSTRUCTIONS IN-5 REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT (a) (b) (c) (d) (e) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Installation and removal of battery terminal: (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 cable. (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. Check hose and wiring connectors to make sure that they are connected securely and correctly. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the syrtftfol. (0 Precoated parts Precoated parts are bolts, 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.
  • 16. IN-6 INTRODUCTION - REPAIR INSTRUCTIONS (3) Precoated parts are indicated in the component il­ lustrations by the syrtfool. (g) When necessary, use a sealer on gaskets to prevent leaks. (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. 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. Illustration Symbol Part Name Abbreviation BE5594 IN0365 FUSE FUSE BE5695 IN0366 MEDIUM CURRENT FUSE M-FUSE BE5596 INO367 HIGH CURRENT FUSE H-FUSE IN0367 FUSIBLE LINK FL BE5698 ......TN036S CIRCUIT BREAKER CB V00076
  • 17. INTRODUCTION REPAIR INSTRUCTIONS IN-7 (k) (I) 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—9). Cancel the parking brake on the level place and shift the transmission in Neutral (or N range). When jacking up the front wheels of the vehicle, at first place stoppers behind the rear wheels. When jacking up the rear wheels of the vehicle, at first place stoppers before the front wheels. When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground. • After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the following parts: (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. (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. (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. (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.
  • 18. IN—8 INTRODUCTION - REPAIR INSTRUCTIONS 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. 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.
  • 19. INTRODUCTION - REPAIR INSTRUCTIONS IN-9 VEHICLE LIFT AND SUPPORT LOCATIONS INOFP-Ot p JACK POSITION ------------------------------------------ Front Front suspension member Rear Lower Back Outer Panel (Protrusion) CAUTION : When jacking-up the front and rear, make sure the vehicle is not carrying any extra weight. PANTOGRAPH JACK POSITION------------ SUPPORT POSITION Safety stand and swing arm type lift o B02414
  • 20. iN-10 Sedan model: do not Jack up Do not jack up JACK POSITION ------------------------------------------- Front Front suspension member Rear Lower Back Outer Panel (Protrusion) CAUTION : When jacking-up the front and rear, make sure the vehicle is not carrying any extra weight. PANTOGRAPH JACK POSITION------------- SUPPORT POSITION Safety stand and swing arm type lift B09701
  • 21. INTRODUCTION REPAIR INSTRUCTIONS IN—11 Hatchback model: Plate type lift HINT: Right and left set position Place the vehicle over the center of the lift. Front and rear set position • When using attachments, place the one for front side vertically and the one for rear side horizontally to the vehicle. • Align the cushion gum ends of the plate with the attachment lower ends (A, C). • Align the attachment upper end (B) with the rocker flange rear side notch. Attachment dimensions 3 B02415
  • 22. IN—12 INTRODUCTION - REPAIR INSTRUCTIONS HINT: Right and left set position Place the vehicle over the center of the lift. Front and rear set position • When using attachments, place the one for front side vertically and the one for rear side horizontally to the vehicle. • Align the cushion gum ends of the plate with the attachment lower ends (A, C). • Align the attachment upper end (B) with the rocker flange rear side notch. Attachment dimensions p. B09700
  • 23. INTRODUCTION FOR ALL OF VEHICLES IN—13 FOR ALL OF VEHICLES PRECAUTION IN0FQ-03 1. (a) (b) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER (See Pub. No. RM685E on page RS-1) The YARIS/ECHO is equipped with an SRS (Supplemen­ tal Restraint System), such as the driver airbag, front pas­ senger airbag assembly, side airbag assembly 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. GENERAL NOTICE (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. RM838E on page DI-159). (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 anoth­ er battery.
  • 24. IN—14 INTRODUCTION - f OF* ALL OF VEHICLE. (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front pas­ senger airbag assembly, side airbag assembly, air­ bag sensor assembly, front airbag sensor, side air­ bag sensor assembly and seat belt pretensioner 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, steering wheel pad, front passenger airbag assembly, side airbag assembly, airbag sensor as­ sembly, front airbag sensor, side airbag sensor as­ sembly or seat belt pretensioner. (7) If the airbag sensor assembly, steering wheel pad, front passenger airbag assembly, side airbag as­ sembly, airbag sensor assembly, front airbag sen­ sor, side airbag sensor assembly or seat belt pre­ tensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or con­ nector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assem­ bly, side airbag assembly, airbag sensor assembly, front airbag sensor, side airbag sensor assembly or seat belt pretensioner to hot air or flames. (9) Use a volt/ohmmeter with high impedance (10 kD/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. RM838E on page DI—159). 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 See Pub. No. RM838E on page SR-9 of this manual concerning correct steering wheel installation.
  • 25. INTRODUCTION FOR ALL OF VEHICLES IN-15 (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 de­ ploys 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. RM685E on page RS-14). Carry out the operation in a safe place away from electrical noise.
  • 26. IN—16 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 deploys. (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 front passenger airbag assembly alone, the airbag should be deployed using an SST before disposal (See Pub. No. RM685E on page RS-27). Perform the operation in a safe place away from electrical noise. Example: Correct o N Wrong X B02420
  • 27. IN-17 INTRODUCTION - FOR ALL OE 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 deploys. (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. RM737E RS-17). Perform the operation in a safe place away from electrical noise. Example: X N21642
  • 28. IN—18 INTRODUCTION - FOR ALLCO/EHICLES (g) SEAT BELT PRETENSIONER (1) Never measure the resistance of the seat belt pre­ tensioner. (This may cause the seat belt pretension­ er to activate, which is very dangerous.) (2) Never disassemble the seat belt pretensioner. (3) Never install the seat belt pretensioner in another vehicle. (4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. (5) When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. (6) When disposing of a vehicle or the seat belt preten­ sioner alone, the seat belt pretensioner should be activated before disposal (See Pub. No. RM685E on page BO-130 and See Pub. No. RM737E on page BO-65). Perform the operation in a safe place away from electrical noise. (7) The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt preten­ sioner. (8) 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.
  • 29. INTRODUCTION FOR ALL QF VEHICLES IN-19 (h) 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. (i) WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire har­ ness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page (See Pub. No. RM737E on page RS-47). 2. 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. (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) Avoid winding the antenna feeder together with other wiring as much as possible, and 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.
  • 30. IN-20 INTRODUCTION - FOR ALL OF VEHICLES 4. FOR USING HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: • 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. 5. FOR VEHICLES EQUIPPED WITH TOYOTA FREE-TRONIC CAUTION: Do not operate the throttle link when the shift lever is in any position other than neutral while the en­ gine is rotating. The vehicle might start suddenly. 6. FOR VEHICLES EQUIPPED WITH TOYOTA STOP AND GO SYSTEM NOTICE: When disconnecting the negative (-) terminal cable from the battery, after completing work, repeat depressing and releasing the clutch pedal in a full degree 10 times or more. Go to Autocarmanual.com for the complete manual