Handling Precautions On Related Components

The brake system is one of the most important safety components. Always follow the directions and notes given in the brake (32) section of the repair manual for the relevant model when handling brake system parts. NOTICE When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC system. The drive train and chassis are components that can have great effects on the running performance and vibration resistance of the vehicle. After installing components in the sections...

Ca

Main Body Ecu Yaris 2007

(a) Disconnect the D31 power steering ECU connector. The resistance must be measured after the D42 P-CAN J C connector is disconnected. REPAIR OR REPLACE CAN MAIN WIRE CONNECTED TO POWER STEERING ECU (P-CAN J C -POWER STEERING ECU (CAN-H, CAN-L)) CHECK CAN BUS LINES FOR SHORT CIRCUIT (MAIN BODY ECU BRANCH WIRE) (a) Disconnect the D33 main body ECU connector.

Read Value Of Data List Skid Control Sensor

(a) Connect the intelligent tester to the DLC3. (b) Start the engine and drive the vehicle. (d) Select the following menu items DIAGNOSIS OBD MOBD select vehicle ABS DATA LIST. (e) Select the item RR (RL) WHEEL SPD in the DATA LIST and read the value displayed on the intelligent tester. Wheel speed sensor (RR) reading min. 0 mph (0 km h), max. 202 mph (326 km h) Similar to speed indicated on speedometer Wheel speed sensor (RL) reading min. 0 mph (0 km h), max. 202 mph (326 km h) Similar to...

Before releasing the parking brake lever set chocks to hold the vehicle for safety

When the parking brake is applied or the brake fluid level is low, the brake warning light comes on. (b) When the ignition switch is turned on, check that the ABS warning light and brake warning light come on and go off in approximately 3 seconds. If the warning lights do not illuminate, confirm whether the bulbs have burned out, and also check for CAN communication system DTCs, since the skid control ECU and combination meter are connected by the CAN communication line. If the warning light...

A A A A

Toyota Yaris Wheel Alignment

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of...

Adhesive Application Area Work Procedure

This vehicle has areas on the Quarter Panel and Quarter Wheel Housing Outer Panel that are joined together only with adhesive. It is necessary to conduct the correct repair procedures for high durability so make sure to follow the instructions below for the adhesive application areas. Type of adhesive used 3M8115 Auto Mix Panel Bond (A) Remove the body sealer from the Quarter Panel and cut at the cut and join location. Remove the spot welded portions. (B) After rough cutting the Wheel Arch...

Air Conditioning Unit for Hatchback Components

FRONT WIPER ARM AND BLADE ASSEMBLY RH FRONT WIPER ARM AND BLADE ASSEMBLY RH COWL TOP NO. 1 VENTILATOR LOUVER CENTER NO. 2 COWL TO REGISTER DUCT SUB-ASSEMBLY COWL TOP NO. 1 VENTILATOR LOUVER CENTER NO. 2 COWL TO REGISTER DUCT SUB-ASSEMBLY N*m (kgf*cm, ft*lbf) Specified torque N*m (kgf*cm, ft*lbf) Specified torque AIR INLET DAMPER CONTROL CABLE SUB-ASSEMBLY DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY AIR MIX DAMPER CONTROL CABLE SUB-ASSEMBLY AIR MIX...

Antirust Treatment After Installation Before Painting Process

(1) For water-proofing and anti-corrosion measures, always apply the body sealer to the body panel seams and hems of the doors, hood, etc. (1) To prevent corrosion and protect the body from damage by flying stones, always apply sufficient under-coating to the bottom surface of the under body and inside of the wheel housings.

Av

Antenna Transfer Assembly Submarines

REMOVE ANTENNA CORD SUB-ASSEMBLY (1) Remove the 6 pieces of tape. (2) Remove the antenna cord from the cutout of the roof headlining. (3) Remove the antenna cord from the 3 claws of the front and rear side rail spacers. (1) Remove the 4 pieces of tape. (2) Remove the antenna cord from the cutout of the roof headlining. (3) Remove the antenna cord from the 5 claws of the front and rear side rail spacers.

Bc

Am2 Fuse Toyota Camry

SKID CONTROL SENSOR WIRE RH SKID CONTROL SENSOR RH SKID CONTROL SENSOR WIRE RH SKID CONTROL SENSOR RH FRONT SPEED SENSOR LH FRONT SPEED SENSOR ROTOR LH ENGINE ROOM R B -ABS1 VSC1 FUSE -ABS2 VSC2 FUSE -AM2 FUSE FRONT SPEED SENSOR LH FRONT SPEED SENSOR ROTOR LH ENGINE ROOM R B -ABS1 VSC1 FUSE -ABS2 VSC2 FUSE -AM2 FUSE

Body Panel Sealing Areas

1) Prior to applying body sealer, clean the area with a rag soaked in silicone remover. 2) If weld-through primer was used, first wipe off any excess and than coat with anti-corrosion primer before applying body sealer. 3) Wipe off excess body sealer with a rag soaked in silicone remover. 4) Besure to repair as necessary if the body sealer shows signs of damage such as peeling or cracking.

Body Panel Under Coating Areas

1) First wipe off any dirt, grease or oil with a rag soaked in silicone remover. 2) Cover the surrounding areas with masking paper to avoid coating unnecessary areas. If other areas are acci-dently coated, wipe off the coating immediately. 3) Apply the first coating of undercoat to all welded areas and panel joints, then apply a second coat over the entire area. 4) Do not coat parts which become hot such as the tailpipe, and moving parts such as the propeller shaft. 5) Apply under coating to...

Check Electrical Door Lock Operation

(a) Check that all doors are locked and unlocked in accordance with the door control switch operation. (b) Check that only the driver side door unlocks when the driver side door lock key cylinder is turned to UNLOCK and all doors unlock when turned to UNLOCK once again within 3 seconds using the key (2-step unlocking function). Doors cannot be locked or unlocked using the key when the ignition switch is on and the driver seat belt is fastened. (c) Check the key lock-in prevention function....

Check Harness And Connector Passenger Side Door Lock Assembly Main Body

Front Door Lock Assembly (Passenger Side) Connector (a) Disconnect the 4H main body ECU connector. (b) Disconnect the F5 front door lock assembly connector. (c) Measure the resistance. Standard resistance 4H-15(UL2) or F5-5(UL) - Body ground (d) Reconnect the main body ECU connector. (e) Reconnect the front door lock assembly connector.

Check Harness And Connector Skid Control Ecu Front Speed Sensor

Skid Control ECU (harness side connector) Front Speed Sensor (harness side connector) (a) Disconnect the skid control ECU connector. (b) Disconnect the front speed sensor connector. (c) Measure the resistance. Standard resistance (LH) REPAIR OR REPLACE HARNESS OR CONNECTOR

Cowl Top Side Upper Panel Assy Sedan

With the cowl top side panel removed. Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply...

Customize Parameters

The following item can be customized. Changes key reminder warning buzzer interval When the customer requests the modification of an item, first make sure that the function can be customized. Be sure to record the current settings before customizing. When troubleshooting a function, first make sure that the function is not set to OFF.

Description

This DTC is output when the refrigerant pressure is either extremely low (0.19 Mpa 2.0 kgf cm2, 28 psi or less) or extremely high (3.14 Mpa 32.0 kgf cm2, 455 psi or more). The pressure sensor, which is installed on the pipe of the high pressure side, detects the refrigerant pressure and sends a refrigerant pressure signal to the air conditioning amplifier. The air conditioning amplifier determines the pressure from the signals in accordance with the sensor characteristics, and controls the...

Disassembly

INSPECT 4TH GEAR THRUST CLEARANCE (a) Using a feeler gauge, measure the 4th gear thrust clearance. 0.1 to 0.55 mm (0.0039 to 0.0217 in.) Maximum clearance 0.55 mm (0.0217 in.) If the clearance exceeds the maximum, replace transmission clutch hub No. 2, the 4th gear or input shaft rear radial ball bearing. 2. INSPECT 3RD GEAR THRUST CLEARANCE (a) Using a dial gauge, measure the 3rd gear thrust clearance. 0.1 to 0.35 mm (0.0039 to 0.0138 in.) Maximum clearance 0.35 mm (0.0138 in.) If the...

Dl

Response to mode selection (Power door lock operation) Add Mode LOCK-UNLOCK operation Once Confirmation Mode LOCK-UNLOCK operation The number of registered codes (1 to 5 times) Rewrite Mode LOCK-UNLOCK operation Twice Prohibition Mode LOCK-UNLOCK operation 5 times T1 Approximately 1 second T2 Approximately 2 seconds In Confirmation Mode, LOCK-UNLOCK operation will occur once for each recognition code that has been registered. For example, if 2 recognition codes have been registered, the...

Do not damage the journal surface of the snap ring

INSPECT 3RD GEAR RADIAL CLEARANCE (a) Using a dial gauge, measure the 3rd gear radial clearance. 0.015 to 0.058 mm (0.0006 to 0.0023 in.) NSK made 0.015 to 0.056 mm (0.0006 to 0.0022 in.) Maximum clearance KOYO made 0.058 mm (0.0023 in.) NSK made 0.056 mm (0.0022 in.) If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. 11. INSPECT 4TH GEAR RADIAL CLEARANCE (a) Using a dial gauge, measure the 4th gear radial clearance. 0.009 to 0.050 mm...

Fail Safe Operation

If there is a problem with any sensor signals or actuator systems, the skid control ECU prohibits the power supply to the brake actuator. ABS control is prohibited, but EBD control continues as far as possible. If EBD control is impossible, the BRAKE warning light comes on to warn the driver (See page BC-24). If any system components have malfunctions before starting control, the operation stops immediately. If any system components have malfunctions during control, the control stops gradually...

Foamed Material Application Areas

Toyota Prius Timing Marks

The sections shown in the figure below are filled with foamed material to provide noise insulation. Refill with foamed materials after repairing these sections and their surrounding sections. HINT 1) Use the service holes located on the reverse side of the body panel to refill foamed materials. 2) Follow manufacturer directions when handling the foamed material.

Front Body Pillar Cut Hatchback

With the cowl top side upper panel removed. 1 *1 This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. 7G mm (2.76 in.) 8G mm (3.15 in.) 1GG mm (3.94 in.) 16G mm (6.3G in.) Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before...

Front Body Pillar Cut Sedan

Frontal Cut Organ

With the cowl top side upper panel removed. 1 After removing A , remove the front body pillar. 2 *1 This part of the outer panel is reused because the rocker panel section is cut off at a position behind the service part cut position of the outer panel. Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects...

Front Door Outer Panel Cut Sedan Ex Usa Canada

Front Door Shuto Guripu

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After applying the top coat, apply anti-rust agent to the internal panel...

Front Sidemember Reinforcement Assy

With the radiator support and front fender apron removed. 1 Remove A at the same time. PART NAME Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the...

Function Of Components

Front speed sensor (Semiconductor speed sensor, magnetic sensor rotor) Detects the wheel speed and sends a signal to the skid control ECU. The front speed sensor (semiconductor speed sensor) with the integrated bearing and the sensor rotor (magnetic sensor rotor) are installed on the front axle hub. The magnetic sensor rotor is equipped with north and south poles (48 of each), which are evenly spaced around its circumference. The magnetic field changes as the magnetic sensor rotor rotates. The...

General Repair Instructions

(1) When welding, protect the painted surfaces, windows, seats and carpet with heat resistant, fireproof covers. (1) Never stand in a direct line with the chain when using a puller on the body or frame, and be sure to attach a safety cable. (2) Before performing repair work, check for fuel leaks. If a leak is found, be sure to close the opening completely. (3) If it is necessary to use a flame in the area of the fuel tank, first remove the tank and plug the fuel line. (1) In addition to the...

Handling Precautions Of Plastic Body Parts

(1) The repair procedure for plastic body parts must conform with the type of plastic material. (2) Plastic body parts are identified by the codes in the following table. (3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, painting etc.), consideration must be given to the properties of the plastic. Heat* resistant temperature limit C ( F) Alcohol is harmless if applied only for short time in small amounts (e.g., quick wiping to remove grease)....

Heat Repair For Body Structure Panels

Toyota prohibits the use of the heat repair method on body structure panels when repairing a vehicle damaged in a collision. Panels that have high strength and rigidity, as well as a long life span for the automobile body are in high demand. At Toyota, in order to fulfill these requirement, we use high tensile strength steel sheets and rust preventive steel sheets on the body. High tensile steel sheets are made with alloy additives and a special heat treatment in order to improve the strength....

Imming

Ignition Switch Toyota Yaris Wiring

(a) Turn the ignition switch OFF. (b) Disconnect the D42 P-CAN J C connector. (c) Measure the resistance. Standard resistance (a) Reconnect the P-CAN J C connector. CHECK CAN MAIN WIRE FOR DISCONNECTION (ECM) (a) Turn the ignition switch OFF. (b) Disconnect the A21 ECM connector. (c) Measure the resistance. Standard resistance CHECK CAN MAIN WIRE FOR DISCONNECTION (D-CAN J C - ECM) (a) Turn the ignition switch OFF. (b) Disconnect the D41 D-CAN J C connector. (c) Measure the resistance. Standard...

Info

DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE FAN AND GENERATOR V BELT (See page EM-7) (b) Separate the connector and the harness clamp. (c) Remove the nut and remove terminal B. (d) Remove fan belt adjusting slider fixing bolts A and B and remove the fan belt adjusting slider. (e) Remove fixing bolt B and remove the generator.

Inspect Door Control Switch for Front Driver Door Side

Door Control Switch (for front driver door side) (a) 3 Door, 5 Door, Sedan w Power window (1) Disconnect the G1 door control switch (for front driver door side) connector. (2) Measure the resistance of the switch. Standard resistance (3 Door) Standard resistance (5 Door, Sedan w Power window) (3) Reconnect the door control switch (for front driver door side) connector. (1) Disconnect the G7 door control switch (for front driver door side) connector. (2) Measure the resistance of the switch....

Inspect Power Window Regulator Master Switch Assembly

(a) Check the resistance of the door control switch. (1) Using an ohmmeter, measure the resistance and check the results in accordance with the value(s) in the table below. Standard Resistance If the result is not as specified, replace the power window regulator master switch.

Inspect Rd Gear Synchronizer Ring

(b) Coat the 3rd gear cone with gear oil. (c) Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone. If the synchronizer outer ring does not lock, replace the synchronizer ring. (e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Standard clearance

Inspect Synchronizer Ring No For Nd Gear

(b) Coat the 2nd gear cone with gear oil. (c) Turn the synchronizer ring in one direction while pushing it against the 2nd gear cone. If the synchronizer ring does not lock, replace the synchronizer ring. (e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Standard clearance

Inspect Synchronizer Ring No For St Gear

Yaris Hybrid Battery Meter

(b) Coat the 1st gear cone with gear oil. (c) Turn the synchronizer ring in one direction while pushing it against the 1st gear cone. If the synchronizer ring does not lock, replace the synchronizer ring. (e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Standard clearance

Inspection

Standard resistance Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. When measuring the resistance, the temperature of the sensor and the cooler thermistor must be the same. As the temperature increases, the resistance If the operation is not as specified, replace the 34.3 mm (1.35 in.)-20.9 mm (0.82 in.)_ 34.3 mm (1.35 in.)-20.9 mm (0.82 in.)_

Inspection Procedure

Turn the ignition switch OFF before measuring the resistances of the CAN main wire and the CAN branch wire. After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not in operation. Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open. HINT...

Inspegtion Progedure

Connector Stop Lamp Switch

(a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (d) Select the following menu items DIAGNOSIS OBD MOBD select vehicle ABS DATA LIST. ON Brake pedal depressed OFF Brake pedal released (e) Check that STOP LAMP SW is turned ON and OFF when the brake pedal is depressed and released. OK STOP LAMP SW is turned ON and OFF in accordance with the operation of the brake pedal. CHECK SKID CONTROL ECU TERMINAL VOLTAGE (STP) Skid Control ECU (harness side connector) (a)...

Install Front Differential Ring Gear

Recondition Battery Guide

(a) Clean the contact surfaces of the front differential case and ring gear. (b) Using a heater, heat the front differential ring gear to 90 to 110 C (194.0 to 230.0 F). (c) After the moisture on the ring gear has completely evaporated, quickly install the ring gear onto the differential case. (d) Aligning the 2 matchmarks, quickly install the front differential ring gear onto the front differential case.

Install Heater Radiator Unit Subassembly

(a) Install the radiator heater unit onto the air conditioner radiator assembly. (b) Engage the 3 clips and install the clamp. 5. INSTALL PTC HEATER ASSEMBLY (for Cold Area Specification Vehicles) (a) Install the PTC heater with the 2 screws. (a) Engage the 3 claws and install the air duct. (a) Engage the 3 claws and install the air duct. 8. INSTALL AIR MIX DAMPER CONTROL CABLE SUBASSEMBLY (a) Engage the claw and install the air mix damper control cable. 9. INSTALL DEFROSTER DAMPER CONTROL...

Installation

(a) Provisionally install the generator with fixing bolt B. (b) Provisionally install the fan belt adjusting slider with fan belt adjusting slider fixing bolts A and B, then move the generator toward the cylinder block and tighten bolt B. Torque 11 N*m (112 kgf*cm, 8.1 ft.*lbf) (c) Install the connector and the wire harness clamp. (d) Install terminal B with the nut. Torque 9.8 N*m (100 kgf*cm, 7.2 ft.*lbf) 2. INSTALL FAN AND GENERATOR V BELT (See page EM-7) 3. ADJUST FAN AND GENERATOR V BELT...

Main body ECU

Driver side door courtesy light switch signal ON or OFF ON Driver side door is open OFF Driver side door is closed Driver side door lock position switch signal ON or OFF ON Driver side door is unlocked OFF Driver side door is locked Door manual lock switch signal ON or OFF ON Door control switch (for front driver door side) is turned to lock position OFF Door control switch (for front driver door side) is turned to unlock position Door manual unlock switch signal ON or OFF ON Door control...

Mm tats mm tats

Copy-protected CDs cannot be played. Dual discs cannot be played. Playing dual discs may cause malfunctions of the CD player. CD-Rs and CD-RWs may not be played depending on the recording conditions or characteristics of the discs, or due to damage, dirt, or deterioration caused by leaving the discs in the cabin for a long time. Unfinalized CD-Rs and CD-RWs cannot be played. PAL or SECAM color television standard discs cannot be played. (Only NTSC discs can be played.) Keep the discs away from...

Notices When Checking

(a) Wireless door LOCK UNLOCK function This function operates only when the vehicle is in its initial condition (the following 3 conditions are met). (1) No key is inserted into the ignition key cylinder. (3) The power door lock system is functioning normally. The UNLOCK function operates even when one of the doors is open. The UNLOCK function operates even when the key is inserted into the ignition key cylinder. However, the ignition switch must be OFF. (b) The operating range differs...

Onvehicle Inspection

Be sure that the ignition is off if you work near the electric cooling fans or radiator grille. With the ignition on the electric cooling fans may automatically start to run if the engine coolant temperature is high and or the air conditioning is on. INSPECT COOLING FAN OPERATION AT LOW TEMPERATURES (Below 83 C (181 F)) (a) Turn the ignition switch on (IG) and air conditioning switch off. (b) Check that the cooling fan stops. If not, check the cooling fan relay and engine coolant temperature...

Part Name

Recondition Battery Guide

A Back Door Opening Lower Reinforcement B Rear Bumper Side Retainer Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding parts. After welding, apply body sealer and undercoating to the corresponding parts. After...

Perform Active Test Using Intelligent Tester Abs Motor Relay

(a) Connect the intelligent tester to the DLC3. (b) Turn the ignition switch on. (d) Clear the DTCs (See page BC-25). (e) Perform the active test using the intelligent tester. Select the following menu items Chassis ABS VSC TRC Active Test. Operating sound of motor can be heard (f) Check for the operation sound of the ABS motor when operating it with the intelligent tester. OK

Point

Before temporarily installing the new parts, apply body sealer to the reinforcement, side impact protection 1) Apply sealer evenly of about 10 mm (0.39 in.) from the flange and 3 mm (0.12 in.) in diameter on the outer panel and apply just enough sealer for the reinforcement and side impact protection beam to make contact. Bend the flange hem about 30 with a hammer and dolly. Then, fasten tightly with a hemming tool. HINT

Problem Symptom Confirmation

(1) Turn the cruise control main switch on. (2) Drive at the required speed between 25 mph (40 km h) and 125 mph (200 km h). (3) Push the cruise control main switch to -(COAST) SET. (4) After releasing the switch, check that the vehicle cruises at the set speed. (b) Inspect the ACCELERATION function. (1) Turn the cruise control main switch on. (2) Drive at the required speed between 25 mph (40 km h) and 125 mph (200 km h). (3) Push the cruise control main switch to -(COAST) SET. (4) Check that...

Pumping speed

1 pumps every second *1 Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criteria 93.3 to 122.7 kPa (0.95 to 1.25 kgf cm2, 13.5 to 17.8 psi) Minimum standard valve (after using cap) If the maximum pressure is less than the specified pressure for the minimum standard valve, replace the radiator cap sub-assembly.

Reassembly

Evap Thermistor Sensor Prius Repl

(a) Install the sensor onto the evaporator as shown in the illustration. (b) Check that the sensor sticks to the evaporator surface as shown in the illustration (A Sensor, B Evaporator). If reusing the evaporator, do not reinsert the sensor in the same position that it was in before. Insert it within area C, shown in the illustration. 2. INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY If a new cooler evaporator is installed, add compressor oil to the cooler evaporator as follows. Compressor oil...

Reconfirm

(a) Clear the DTC(s) (See page BC-25). (c) Drive the vehicle at a speed of 12 mph (20 km h) or more for at least 60 seconds. (d) Check if the same DTC(s) is output (See page BC-25). CHECK FRONT SPEED SENSOR INSTALLATION (a) Check that the speed sensor installation bolt is tightened properly. OK The installation bolt is tightened properly. Torque 8.5 N*m (87 kgf*cm, 75 in.*lbf) (a) Visually check the speed sensor for deformation and damage. OK No gap between the sensor and front steering (a)...

Removal

Some of these service operations affect the SRS airbag system. Read the precautionary notices concerning the SRS airbag system before servicing (See pageRS-1 ). Use the same procedure for both the RH and LH sides. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Wait for at least 90 seconds after disconnecting the cable to prevent the airbag from working. 2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-66) 3. DRAIN ENGINE COOLANT (for 1NZ-FE) (See page CO-8) 4. DISCONNECT...

Remove Check Function

(a) Check that the key reminder warning buzzer sounds. (1) With the driver side door closed, insert the key into the ignition key cylinder and then turn the key to LOCK or ACC. (2) Check that the buzzer sounds intermittently when the driver side door is open. (b) Check that the key reminder warning buzzer stops. (1) Check that the buzzer stops sounding if any of the following operations is performed while the buzzer is sounding Close the driver side door (front door courtesy switch is off)....

Remove Door Control Switch

(a) for Front passenger side with power window Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the door control switch. Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the door control switch.

Remove Instrument Panel Reinforcement

(b) Remove the bolt and disconnect the ground wire. (e) Disconnect the connectors and clamps. for Cold Area Specification Vehicles (g) Remove the 9 bolts and remove the instrument panel reinforcement together with the air conditioning unit. (h) Disconnect the connector and the 3 clamps. (i) Remove the 3 screws and the air conditioning unit.

Remove Rd Gear

(a) Using 2 screwdrivers and a hammer, remove the clutch hub No. 2 setting shaft snap ring from the input shaft. HINT Use a shop rag or piece of cloth to keep the snap ring from flying off. (b) Using SST and a press, remove transmission clutch hub No. 2 and the 3rd gear from the input shaft. SST 09950-00020 NOTICE Do not tighten SST excessively. Support the input shaft by hand to prevent it from dropping off. 9. REMOVE 3RD GEAR SYNCHRONIZER RING (a) Remove synchronizer ring No. 2 from the 3rd...

Remove St Gear Thrust Washer

(a) Remove the 1st gear thrust washer from the output shaft. 14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL (a) Remove the 1st gear thrust washer pin or ball from the output shaft. (a) Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from transmission clutch hub No. 1. NOTICE Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying off.

Remove Th Gear

(a) Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft. HINT Use a shop rag or piece of cloth to keep the snap ring from flying off. (b) Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft. SST 09950-00020 HINT Do not tighten SST excessively. Support the input shaft assembly by hand to prevent it from dropping off.

Result

Doors cannot be locked using door control switch (for front driver door side) Doors cannot be locked using driver side door key cylinder Doors cannot be locked using door control switch (for center console side) Doors cannot be locked using front passenger side door key cylinder Doors cannot be locked using door control switch (for passenger side)

Section categories

This manual has been divided as shown below. Explanation of general body repair. Views of weld panel replacement instructions. Views of weld panel replacement instructions. Instructions for replacing the weld panels from the white body condition, from which bolted parts have been removed, with individual supply parts. Front side member replacement. Quarter panel replacement. Scope and type of anti-rust treatment, etc. together with weld panel replacement.

Sst

(b) Apply chalk to the flat tip of the SST rod. Turn SST upside down and measure the clearance between the brake booster push rod and SST. Standard Clearance -0.21 to 0 mm (-0.0083 to 0 in.) If there is clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient. (c) If the clearance is not within the standard, adjust the length by holding...

Standard fluid pressure

(1) Install SST and the bleed the air. SST 09709-29018 (2) Raise the front brake caliper pressure and inspect the rear wheel cylinder pressure. When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left rear together. If the rear wheel cylinder pressure is incorrect, replace the proportioning valve. (3) Remove SST. (d) Install the bleeder plug onto the front brake caliper and rear wheel cylinder. Torque 8.3 N*m (85 kgf*cm, 73 in.*lbf) (e)...

Standard

If the result is not as specified, there may be a malfunction in the wire harness. (c) Reconnect the door control receiver connector. (d) Measure the voltage of the wire harness side connectors. Transmitter switch ON OFF (No key in ignition key cylinder, all doors closed) Transmitter switch ON OFF (No key in ignition key cylinder, all doors closed) If the result is not as specified, there may be a malfunction in the wire harness.

Standard voltage

Driver side door courtesy switch input Driver side door courtesy switch input Passenger side door courtesy switch input Passenger side door courtesy switch input Rear LH and RH door courtesy switch input Rear LH and RH door courtesy switch input Transmitter switch ON OFF (No key in ignition key cylinder, all doors closed) Transmitter switch ON OFF (No key in ignition key cylinder, all doors closed) *3 Hatchback, Sedan except *5 *4 Sedan *5 *5 Cold area specification, w Engine immobilizer...

System Description

Corvette Front Shims

(a) The air conditioning system has the following features The air conditioning amplifier controls the operation of parts, such as the air conditioning compressor, automatically in accordance with the operating conditions of the air conditioning system. 2. MODE POSITION AND DAMPER OPERATION Continuously changes mix ratio of warm and cool air between COOL and HOT. Blows air from center register and side registers. Blows air from center register, side registers, front footwell register and rear...

Terminals Of

Turn the ignition switch off before measuring the resistances of the CAN main wire and the CAN branch wire. After the ignition switch is turned off, check that the key reminder warning system and light reminder warning system are not in operation. Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches or the doors. If doors need to be opened in order to check connectors, open the doors and leave them open....

Torque Nm kgfcm ftlbf

(3) After adjusting the pedal free play, check the pedal height. 3. INSPECT AND ADJUST CLUTCH RELEASE POINT (1) Pull the parking brake lever and install a wheel stoppers. Start the engine and run it at idle. Without depressing the clutch pedal, slowly move the shift lever into reverse until the gears come into contact. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position. Standard distance...

When cooling is insufficient

Condition Air conditioning system does not function effectively. Pressure low on both low and high pressure sides Cooling performance insufficient Gas leakage from refrigeration system 1. Check for gas leakage using gas leak detector, and repair if necessary 2. Supply appropriate volume of new refrigerant 3. If indicated pressure value close to 0 when connected to gauge, create vacuum after inspecting and repairing location of leakage (4) When the circulation of the refrigerant is poor...

When replacing any parts turn the ignition switch off

If no abnormality is found when inspecting parts, check the skid control ECU and check for poor contact at ground points. If a DTC is displayed during the DTC check, check the circuit for the DTC listed in the table below. For details of each DTC, refer to the page indicated. When 2 or more DTCs are detected, perform circuit inspections one by one until the problem is identified. All DTCs in the table below are detected in accordance with 1 trip detection logic.

When the refrigerant does not circulate

Condition Air conditioning system does not function or functions intermittently. Vacuum indicated on low pressure side, and extremely low pressure indicated on high pressure side Frost or condensation seen on piping on both sides of condenser or expansion valve Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leakage from expansion valve 2. Clean expansion valve with compressed air 4. Evacuate air and then supply appropriate volume of...

When there is moisture in the refrigeration system

Tabel Volume Refrigant Toyota Avanza

During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing temporary interruption of cycle However, when melted, returns to normal condition Receiver dryer oversaturated Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation 2. Remove moisture from cycle by repeatedly evacuating air 3. Supply appropriate volume of new refrigerant

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Toyota Yaris Panel Removal

COWL TOP SIDE PANEL (ASSY) Hatchback Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer,...

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1 Remove B before conducting this work. 2 Remove a at the same time. PART NAME A Front Sidemember Outer Plate B Engine Front Mounting Bracket Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After...

Problem Symptoms Table

Use the table below to help you find the cause of the problem. The numbers indicate the ranked order of probability of each of the possible causes. Check each part in the order suggested. If necessary, replace the applicable parts. 2. Parking brake lever travel (Out of adjustment) 3. Rear drum brake shoe clearance (Out of adjustment) 5. Brake shoe (Cracked or distorted) 10. Tension or return spring (Faulty) 10. Brake shoe (Cracked or distorted) 6. Brake shoe (Cracked or distorted) 2. Brake shoe...

If the system cannot enter selfdiagnostic mode the system returns to normal mode

(b) Check that the system has switched to self-diagnostic mode by checking the flash pattern of the interior light. (c) Check the diagnostic outputs when the door control transmitter switch is held down. The diagnostic outputs can be checked by the flash patterns of the interior light. No Diagnosis Output T1 025 seconds

Yaris Manual Shift Cable

INSTALL FLOOR SHIFT SHIFT LEVER ASSEMBLY (a) Install the shift lever with the 4 bolts. Torque 12 N*m (122 kgf*cm, 8.9 ft.*lbf) CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (a) Install the control shift cable onto the shift lever Install the cable with the protruding portion of the cable outer facing upward. After installing, check that the lock of the cable outer is protruding beyond portion A, as shown in the illustration. Connect the control shift cable to the shift lever. Install the control...

Parts Location

Toyota Yaris D4d Main Fuse

- HEATER CONTROL (BLOWER SWITCH) - HEATER CONTROL (BLOWER SWITCH) - HEATER CONTROL BASE (A C SWITCH) - NO. 3 HEATER CONTROL KNOB (MAX HOT SWITCH*) - HEATER CONTROL (BLOWER SWITCH) - HEATER CONTROL BASE (A C SWITCH) - NO. 3 HEATER CONTROL KNOB (MAX HOT SWITCH*) NO. 1 COOLER THERMISTOR (EVAPORATOR TEMPERATURE SENSOR) NO. 1 COOLER THERMISTOR (EVAPORATOR TEMPERATURE SENSOR)

Inspect Th Gear Synchronizer Ring

Synchronizer Ring Gear

(b) Coat the 4th gear cone with gear oil. (c) Turn the synchronizer ring in one direction while pushing it against the 4th gear cone. If the synchronizer outer ring does not lock, replace the synchronizer ring. (e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Standard clearance

Dtc Check Clear

(a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Read the DTC by following the prompts on the tester screen. Refer to the intelligent tester operator's manual for further details. (a) Connect the intelligent tester with the CAN VIM to the DLC3. (b) Turn the ignition switch ON and turn the intelligent tester ON. (c) Clear the DTC by following the prompts on the tester screen. Refer to the intelligent tester...

SAE J or Fmvss No DOT

Yaris Brake Pedal

N*m (kgf*cm, ft.*lbf) Specified torque N*m (kgf*cm, ft.*lbf) Specified torque FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP LH FRONT DOOR OPENING TRIM WEATHERSTRIP RH LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY INSTRUMENT PANEL...

Install No Air Duct

(a) Engage the 3 claws and install the air duct. 7. INSTALL AIR MIX DAMPER CONTROL CABLE SUBASSEMBLY (a) Engage the claw and install the air mix damper control cable. 8. INSTALL DEFROSTER DAMPER CONTROL CABLE SUB-ASSEMBLY (a) Engage the claw and install the defroster damper control cable.

ECM Cruise Control System

Vehicle speed min. 0 km h (0 mph) max. 255 km h (158 mph) Vehicle speed min. 0 km h (0 mph) max. 255 km h (158 mph) Actual vehicle speed stored in memory Throttle operating angle min. 0 deg. max. 125 deg. ON Cruise control is SET OFF Cruise control is UNSET ON Cruise control is SET OFF Cruise control is UNSET Switch indicator (Main CPU) ON or OFF ON Switch indicator (Main CPU) is SET OFF Switch indicator (Main CPU) is UNSET Switch indicator (Sub CPU) ON or OFF ON Switch indicator (Sub CPU) is...

Inspect Transmission Hub Sleeve No

How Calculate Offset Idler Gears

(a) Check the sliding condition between transmission hub sleeve No. 3 and transmission clutch hub No. 3. (b) Check that the edges of the transmission hub sleeve No. 3 spline gear are not worn down. (c) Using vernier calipers, measure the width of the transmission hub sleeve No. 3 groove (A) and the thickness of the claw part on the gear shift fork No. 3 (B), and calculate the clearance. Standard clearance (A - B) 0.3 to 0.5 mm (0.012 to 0.0020 in.) If the clearance exceeds the standard, replace...

Front Door Outer Panel Cut Hatchback Door

Manual Control Panel Toyota Yaris

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply the polyurethane foam to the corresponding parts. After welding, apply body sealer and under-coating to the corresponding parts. After applying the top coat layer, apply anti-rust agent to the inside of...

Installing Toyota Rectifier

Installing Toyota Rectifier

INSPECT GENERATOR BRUSH HOLDER ASSEMBLY (a) Using vernier calipers, measure the exposed brush length. 9.5 to 11.5 mm (0.374 to 0.453 in.) Minimum exposed length 1.5 mm (0.059 in.) If the exposed length is less than the minimum, replace the generator brush holder assembly. 2. INSPECT GENERATOR REGULATOR ASSEMBLY (a) Using an ohmmeter, check the continuity between terminals F and B. When the positive and negative poles between terminals F and B are exchanged, there is continuity in one direction...

Repair Manual Toyota Yariz Engine Torque

INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (a) Install the clutch release cylinder with the 2 bolts. Torque 12 N*m (120 kgf*cm, 8.7 ft.*lbf) 2. CONNECT CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (a) Using SST, connect the flexible hose tube. SST 09023-00101 Torque 15 N*m (153 kgf*cm, 11 ft.*lbf) (a) Fill the brake reservoir tank with brake fluid and bleed the clutch system. Torque 8.3 N*m (85 kgf*cm, 73 in.*lbf) 4. CHECK FOR CLUTCH FLUID LEAKAGE

Cruise Control System

The cruise control system makes it possible to drive at a desired speed without using the accelerator pedal. The ECM controls the throttle opening angle based on signals from switches and sensors. The microcomputer which controls the cruise control system is built into the ECM, and uses is the throttle position sensor and motor as the actuator. Constant speed control gets ready when the cruise control main switch ON-OFF button is pushed (the CRUISE MAIN indicator light comes on). By operating...

Bus Check

(a) Select BUS CHECK from the OBD MOBD MENU screen. HINT The ECUs and sensors that are properly connected to the CAN communication system can be displayed using the intelligent tester via the CAN VIM. (b) Press ENTER on the intelligent tester via the CAN VIM. Name of ECU 1 Name of ECU 2 Name of ECU 3 Name of ECU 4 Name of ECU 5 (c) The screen displays the ECUs and sensors that are properly connected to the CAN communication system. HINT If any properly connected ECUs or sensors are not...

Center Body Pillar Cut Sedan

Toyota Yaris Panel Removal

30 mm (1.18 in.) 40 mm (1.57 in.) 70 mm (2.76 in.) 90 mm (3.54 in.) 1 *1 Take care not to damage the internal reinforcement. 15 mm (0.59 in.) 130 mm (5.12 in.) Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension diagram. (See the body dimension diagram) Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the finish. After welding, apply polyurethane foam to the corresponding...

Preparation For Installation

Recondition Battery Guide

(1) When welding panels with a combined thickness of over 3 mm (0.12 in.), use a MIG (Metal Inert Gas) welder for plug welding. HINT Spot welding does not provide sufficient durability for panels with a combined thickness of over 3 mm (0.12 in.). (b) APPLICATION OF WELD-THROUGH PRIMER (SPOT SEALER) (1) Remove the paint from the portion of the new parts and body to be welded, and apply weld-through primer. (1) For areas where a spot welder cannot be used, use a puncher or drill to make holes for...

How To Proceed With Troubleshooting

Use these procedures to troubleshoot the air conditioning system. Use an intelligent tester in steps 4, 5 and 7. CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK If the voltage is below 11 V, recharge or replace the battery before proceeding. (a) Use an intelligent tester to check if the CAN communication system is functioning. Result (a) Check for DTCs and write down any DTCs that are output. (c) Referring to the DTCs written above, simulate the DTC output conditions and check whether any DTCs of...

Read Data List

Using the intelligent tester's DATA LIST allows switch, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester with CAN VIM to the DLC3. (b) Turn the ignition switch ON. Unlock warning switch signal ON or OFF ON Key is in ignition key cylinder OFF No key is in ignition key cylinder Driver side door courtesy switch signal ON Driver side door is open OFF Driver side door is...

Read Value Of Data List Front Speed Sensor

(a) Connect the intelligent tester to the DLC3. (b) Start the engine and drive the vehicle. (d) Select the following menu items DIAGNOSIS OBD MOBD select vehicle ABS DATA LIST. (e) Select the item FR (FL) WHEEL SPD in the DATA LIST and read the value displayed on the intelligent tester. Wheel speed sensor (FR) reading min. 0 mph (0 km h), max. 202 mph (326 km h) Similar to speed indicated on speedometer Wheel speed sensor (FL) reading min. 0 mph (0 km h), max. 202 mph (326 km h) Similar to...

Install Brake Booster

Taurus Brake Booster Rod Adjustment

(a) Provisionally install the push rod clevis onto the brake booster. Tighten the push rod lock nut when adjusting the brake pedal height. (b) Install a new gasket onto the brake booster. (c) Install the brake booster with the 4 nuts. Torque 9.0 N*m (92 kgf*cm, 80 in.*lbf) (d) Connect the vacuum hose to the vacuum check valve with the clip. (1) Using SST, install the brake tube assembly onto the proportioning valve. SST 09023-00100 Torque for use without SST 15 N*m (155 kgf*cm, 11 ft.*lbf) for...

Toyota Yaris Radiator Installation

Vauxhall Corsa Diesel Engine Diagram

(a) Install the radiator drain cock onto the radiator assembly. 2. INSTALL RADIATOR RESERVE TANK HOSE GROMMET (a) Install the 2 radiator reserve tank hose grommets onto the radiator assembly. (a) Install the 2 radiator support cushions onto the radiator assembly. (a) Engage the 2 claws and install the fan shroud. 5. INSTALL OIL COOLER INLET HOSE (for Automatic Transaxle) (a) Install the oil cooler inlet hose with the clip. 6. INSTALL OIL COOLER OUTLET HOSE (for Automatic Transaxle) (a) Install...

Function Of Main Component

Door control switch (for front driver door side) on master switch locks unlocks all doors Detects door status (open or closed) and outputs data to integration relay Turns on when door is open and off when door is closed Built-in motor locks unlocks door Built-in door control switch (key-linked) detects door lock status (locked or unlocked) and outputs data to integration relay Passenger door, rear LH door, rear RH door and back door locks Built-in motor locks unlocks doors