Toyota Avensis (T250) - Workshop Manual / Repair Manual

TOYOTA AVENSIS - SERVICE MANUAL

- English Workshop Manual in PDF format to vehicles Toyota Avensis.

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INDEX:

EXTERIOR APPEARANCE
MODEL CODE
MODEL LINE-UP
EXTERIOR

EXTERIOR
Front View
Rear View
Side View
Tire & Disc Wheel

INTERIOR

INTERIOR
Instrument Panel
Steering Wheel
Seat
Luggage

EQUIPMENT

EQUIPMENT
Multi Display
Audio System
Multi-information Display
Air Conditioner System
Windshield & Door Glass
Rear Sunshade
Power Outlet
Wiper System

PERFORMANCE

PERFORMANCE
Power Train
Chassis

SAFETY

SAFETY
SRS (Supplemental Restraint System) Airbag System

DIMENSIONS
EQUIPMENT LIST

ENGINE

1ZZ-FE AND 3ZZ-FE ENGINE

Description
Major Difference
Features of 1ZZ-FE and 3ZZ-FE Engine
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Ignition System
Starting System
Serpentine Belt Drive System
Engine Control System

1AZ-FE ENGINE

Description
Major Difference
Features of 1AZ-FE Engine
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Ignition System
Starting System
Serpentine Belt Drive System
Engine Control System

1AZ-FSE ENGINE

Description
Major Difference
Features of 1AZ-FSE Engine
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Ignition System
Starting System
Serpentine Belt Drive System
Engine Control System

1CD-FTV ENGINE

Description
Major Difference
Features of 1CD-FTV Engine
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Charging System
Engine Control System

CHASSIS

CLUTCH

Description
Clutch Master Cylinder
Clutch Start System

MANUAL TRANSAXLE

Description
E354 and E357 Manual Transaxles

AUTOMATIC TRANSAXLE

Description
U241E Automatic Transaxle
U341E Automatic Transaxle
Shift Control Mechanism

SUSPENSION AND AXLE

Suspension
Axle

DRIVE SHAFT







Description

BRAKE

Description
Major Difference (from Previous Model)
Brake Control System (ABS with EBD)
Brake Control System (ABS with EBD, BRAKE ASSIST, TRC, and VSC)

STEERING

Description
Hydraulic Power Steering
EPS (Electric Power Steering)

BODY

BODY STRUCTURE

Lightweight And Highly Rigid Body
Safety Features
Rust-resistant Body
Low Vibration And Low Noise Body
Aerodynamics

ENHANCEMENT OF PRODUCT APPEAL

Parts With Low Repair Costs
Seat Belt

BODY ELECTRICAL

MULTIPLEX COMMUNICATION

Description
Layout of BEAN Component
Layout of AVC-LAN Component
Basic of MPX
Diagnosis

LIGHTING

Description
Headlight Beam Level Control
HID Headlight System
Daytime Running Light System
Illuminated Entry System
Light Reminder System

METER

Combination Meter

WIPER AND WASHER

Description
Layout of Main Component
Raindrop Sensing Function

AIR CONDITIONER

Description
Major Difference (from Previous Model)
Refrigeration Cycle
System Diagram

Layout of Main Component
Mode Position and Damper Operation
Air Outlets and Air Volume Rations
Construction and Operation
Air Conditioner Control
Combustion Type Power Heater

MULTI DISPLAY

Description
Layout of Main Component
Navigation Screen Display
Trip Information Display
Diagnosis Screen Display

MULTI-INFORMATION DISPLAY

Description
Function of Component

AUDIO SYSTEM

Description
Steering Pad Switch

POWER WINDOW SYSTEM

Description
Power Window Motor

DOOR LOCK SYSTEM

Description

ELECTRONIC LUGGAGE/BACK DOOR OUTSIDE HANDLE SYSTEM

Description
Layout of Main Component

WIRELESS DOOR LOCK REMOTE CONTROL SYSTEM

Description
Layout of Main Component
Function

ENGINE IMMOBILISER SYSTEM

Description
Layout of Main Component

THEFT DETERRENT SYSTEM

Description
Layout of Main Component
Construction and Operation
System Operation

SRS AIRBAG SYSTEM

Description
Major Difference (from Previous Model)
Airbag for Frontal Collision
Airbag for Side/Rear Side Collision
Diagnosis

SEAT BELT REMINDER SYSTEM

Description
Occupant Detection Sensor

MOON ROOF SYSTEM

Description
Jam Protection Detection Mechanism

CRUISE CONTROL SYSTEM

Description
Layout of Main Component
Function

AUTOMATIC GLARE-RESISTANT EC MIRROR

Description
Function of Component
Reflection Rate Control

OUTSIDE REAR VIEW MIRROR

Description

FRONT WIPER DEICER SYSTEM

Description

REAR DEFOGGER SYSTEM

Description

POWER SEAT

Description

SEAT HEATER

Description

HEADLIGHT CLEANER

Description

FUEL LID OPENER

Description
Layout of Main Component

Appendix

New Car Features ( 2003.7 - )

OUTLINE OF NEW FEATURES
MODEL CODE
MODEL LINE-UP
NEW FEATURES

ALL ENGINES
2AZ-FSE ENGINE

General
Major Difference (from 1AZ-FSE Engine)
Features of 2AZ-FSE Engine
Engine Proper
Valve Mechanism
Lubrication System
Cooling System
Intake and Exhaust System
Fuel System
Ignition System
Starting System
Serpentine Belt Drive System
Engine Control System

1CD-FTV ENGINE with D-CAT

General
D-CAT System
Major Difference
Features of 1CD-FTV Engine with D-CAT
Engine Proper
Intake and Exhaust System
Fuel System
Engine Control System

U151E AUTOMATIC TRANSAXLE

General
Torque Converter
Oil Pump
Planetary Gear Unit
Valve Body Unit
Electric Control System
Shift Control Mechanism
ATF Warmer

MAJOR TECHNICAL SPECIFICATIONS

New Car Features ( 2004.2 - )

Introduction

OUTLINE OF NEW FEATURES
MODEL CODE
MODEL LINE-UP

NEW FEATURES

1ZZ-FE AND 3ZZ-FE ENGINES

Description
Intake System
Engine Control System

Appendix

MAJOR TECHNICAL SPECIFICATIONS

Repair Manual

INTRODUCTION

HOW TO USE THIS MANUAL

GENERAL INFORMATION
GENERAL INFORMATION ( 2003.7 - )
GENERAL INFORMATION ( 2004.2 - )

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND SERIAL NUMBERS
VEHICLE IDENTIFICATION AND SERIAL NUMBERS ( 2003.7 - )
VEHICLE IDENTIFICATION AND SERIAL NUMBERS ( 2004.2 - )

REPAIR INSTRUCTION

PRECAUTION
PRECAUTION ( 2003.7 - )
PRECAUTION ( 2004.2 - )
VEHICLE LIFT AND SUPPORT LOCATIONS
VEHICLE LIFT AND SUPPORT LOCATIONS ( 2003.7 - )
VEHICLE LIFT AND SUPPORT LOCATIONS ( 2004.2 - )

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

GENERAL INFORMATION
GENERAL INFORMATION ( 2003.7 - )
GENERAL INFORMATION ( 2004.2 - )
HOW TO PROCEED WITH TROUBLESHOOTING
HOW TO PROCEED WITH TROUBLESHOOTING ( 2003.7 - )
HOW TO PROCEED WITH TROUBLESHOOTING ( 2004.2 - )
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
ELECTRONIC CIRCUIT INSPECTION PROCEDURE ( 2003.7 - )
ELECTRONIC CIRCUIT INSPECTION PROCEDURE ( 2004.2 - )

TERMS

ABBREVIATIONS USED IN THIS MANUAL
ABBREVIATIONS USED IN THIS MANUAL ( 2003.7 - )
ABBREVIATIONS USED IN THIS MANUAL ( 2004.2 - )
GLOSSARY OF SAE AND TOYOTA TERMS
GLOSSARY OF SAE AND TOYOTA TERMS ( 2003.7 - )
GLOSSARY OF SAE AND TOYOTA TERMS ( 2004.2 - )

PREPARATION

DIAGNOSTICS

PREPARATION
PREPARATION ( 2003.7 - )
PREPARATION ( 2004.2 - )


ENGINE CONTROL SYSTEM

PREPARATION
PREPARATION ( 2003.7 - )
PREPARATION ( 2004.2 - )

FUEL

PREPARATION
PREPARATION ( 2003.7 - )

EMISSION CONTROL

PREPARATION ( 2003.7 - )

INTAKE

PREPARATION
PREPARATION ( 2003.7 - )

ENGINE MECHANICAL

PREPARATION
PREPARATION ( 2003.7 - )
PREPARATION ( 2004.2 - )

EXHAUST

PREPARATION
PREPARATION ( 2003.7 - )

COOLING

PREPARATION
PREPARATION ( 2003.7 - )
PREPARATION ( 2004.2 - )

LUBRICATION

PREPARATION
PREPARATION ( 2003.7 - )

IGNITION

PREPARATION
PREPARATION ( 2003.7 - )

STARTING & CHARGING

PREPARATION
PREPARATION ( 2003.7 - )

FRONT SUSPENSION

PREPARATION
PREPARATION ( 2003.7 - )

REAR SUSPENSION

PREPARATION

TIRE & WHEEL

PREPARATION

PREPARATION ( 2003.7 - )

DRIVE SHAFT / PROPELLER SHAFT

PREPARATION
PREPARATION ( 2003.7 - )

BRAKE

PREPARATION
PREPARATION ( 2003.7 - )

PARKING BRAKE

PREPARATION

AUTOMATIC TRANSMISSION / TRANS

PREPARATION
PREPARATION ( 2003.7 - )

MANUAL TRANSMISSION / TRANSAXLE

PREPARATION

CLUTCH

PREPARATION

STEERING COLUMN

PREPARATION

POWER STEERING

PREPARATION

HEATER & AIR CONDITIONER

PREPARATION
PREPARATION ( 2003.7 - )

SUPPLEMENTAL RESTRAINT SYSTEM

PREPARATION
PREPARATION ( 2004.2 - )

WIPER & WASHER

PREPARATION

AUDIO & VISUAL SYSTEM

PREPARATION

COMMUNICATION SYSTEM

PREPARATION

WINDSHIELD/WINDOWGLASS / MIRROR

PREPARATION

INSTRUMENT PANEL/METER

PREPARATION
PREPARATION ( 2004.2 - )

SEAT

PREPARATION

SLIDING ROOF / CONVERTIBLE

PREPARATION

ENGINE HOOD / DOOR

PREPARATION

EXTERIOR / INTERIOR TRIM

PREPARATION

VEHICLE CONTROL SYSTEM

PREPARATION

SERVICE SPECIFICATIONS

STANDARD BOLT

HOW TO DETERMINE BOLT STRENGTH
HOW TO DETERMINE BOLT STRENGTH ( 2003.7 - )
HOW TO DETERMINE BOLT STRENGTH ( 2004.2 - )
SPECIFIED TORQUE FOR STANDARD BOLTS
SPECIFIED TORQUE FOR STANDARD BOLTS ( 2003.7 - )
SPECIFIED TORQUE FOR STANDARD BOLTS ( 2004.2 - )

HOW TO DETERMINE NUT STRENGTH
HOW TO DETERMINE NUT STRENGTH ( 2003.7 - )
HOW TO DETERMINE NUT STRENGTH ( 2004.2 - )

ENGINE CONTROL SYSTEM

SERVICE DATA
SERVICE DATA ( 2003.7 - )
SERVICE DATA ( 2004.2 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )
TORQUE SPECIFICATION ( 2004.2 - )

FUEL

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

EMISSION CONTROL

SERVICE DATA
SERVICE DATA ( 2003.7 - )

INTAKE

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

ENGINE MECHANICAL

SERVICE DATA
SERVICE DATA ( 2003.7 - )
SERVICE DATA ( 2004.2 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )
TORQUE SPECIFICATION ( 2004.2 - )


EXHAUST

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

COOLING

SERVICE DATA
SERVICE DATA ( 2003.7 - )
SERVICE DATA ( 2004.2 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

TORQUE SPECIFICATION ( 2004.2 - )

LUBRICATION

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

IGNITION

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

STARTING & CHARGING

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

FRONT SUSPENSION

SERVICE DATA
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

REAR SUSPENSION


SERVICE DATA
TORQUE SPECIFICATION

TIRE & WHEEL

SERVICE DATA
SERVICE DATA ( 2003.7 - )

DRIVE SHAFT / PROPELLER SHAFT /AXLE

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

BRAKE

SERVICE DATA
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

PARKING BRAKE

SERVICE DATA
TORQUE SPECIFICATION

AUTOMATIC TRANSMISSION / TRANSAXLE

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )


MANUAL TRANSMISSION / TRANSAXLE

SERVICE DATA
TORQUE SPECIFICATION

CLUTCH

SERVICE DATA
TORQUE SPECIFICATION

STEERING COLUMN

SERVICE DATA
TORQUE SPECIFICATION

POWER STEERING

SERVICE DATA
TORQUE SPECIFICATION

HEATER & AIR CONDITIONING

SERVICE DATA
SERVICE DATA ( 2003.7 - )
TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2003.7 - )

SUPPLEMENTAL RESTRAINT SYSTEM

TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2004.2 - )

SEAT BELT

TORQUE SPECIFICATION

LIGHTING

TORQUE SPECIFICATION

WIPER & WASHER

TORQUE SPECIFICATION

AUDIO & VISUAL SYSTEM

TORQUE SPECIFICATION

COMMUNICATION SYSTEM

TORQUE SPECIFICATION

WINDSHIELD/WINDOWGLASS / MIRROR

TORQUE SPECIFICATION

INSTRUMENT PANEL/METER

TORQUE SPECIFICATION
TORQUE SPECIFICATION ( 2004.2 - )

SEAT

TORQUE SPECIFICATION

SLIDING ROOF / CONVERTIBLE

TORQUE SPECIFICATION

ENGINE HOOD / DOOR

TORQUE SPECIFICATION

EXTERIOR / INTERIOR TRIM

TORQUE SPECIFICATION

DIAGNOSTICS


SFI SYSTEM (1ZZ-FE/3ZZ-FE)

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0100
P0110
P0115
P0116
P0120
P0121
P0125
P0130
P0133

P0135
P0171
P0300
P0325
P0335
P0340
P0420
P0443
P0500
P0505
P1300
P1346
P1349
P1520
P1600
P1656
ECM POWER SOURCE CIRCUIT
FUEL PUMP CONTROL CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT
TC TERMINAL CIRCUIT


SFI SYSTEM (1ZZ-FE/3ZZ-FE)(From February, 2004)

PRECAUTION
LOCATION
SYSTEM DIAGRAM
HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
CHECK FOR INTERMITTENT PROBLEMS
BASIC INSPECTION
PROBLEM SYMPTOMS TABLE
TERMINALS OF ECM
DIAGNOSIS SYSTEM
DTC CHECK/CLEAR
CHECK MODE PROCEDURE
FAIL-SAFE CHART
DATA LIST/ACTIVE TEST
DIAGNOSTIC TROUBLE CODE CHART
P0010
P0011
P0016
P0031
P0037
P0100
P0110
P0115
P0116
P0120
P0121
P0130
P0133
P0134
P0136
P0171
P0300
P0325
P0335

P0340
P0351

P0420
P0443
P0500
P0504
P0505
P0560
P0604
P0617
P2102
P2111
P2118
P2119
P2120
P2121
ECM POWER SOURCE CIRCUIT
FUEL PUMP CONTROL CIRCUIT
MIL CIRCUIT

SFI SYSTEM (1AZ-FE)

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK

PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0010/39
P0011/59
P0016/18
P0031/21
P0100/31
P0110/24
P0115/22
P0120/41
P0136/27
P0141/27
P0325/52
P0335/12
P0340/12
P0351/14
P0500/42
P0511/33
P0606/89
P2237/21
ECM POWER SOURCE CIRCUIT
ECM BACK-UP POWER SOURCE CIRCUIT
FUEL PUMP CONTROL CIRCUIT
FUEL INJECTOR CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT
TC TERMINAL CIRCUIT
VARIABLE RESISTOR CIRCUIT


SFI SYSTEM (1AZ-FSE)

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0010
P0011
P0016
P0031
P0100
P0105
P0110
P0115
P0116
P0120
P0121
P0130
P0133
P0134
P0136
P0171
P0190
P0191
P0200
P0300
P0325
P0335
P0340
P0351
P0420
P0443
P0500
P0504
P0555
P0556
P0560
P0604
P0617
P0705
P0724
P1235
P2008
P2102
P2111
P2118
P2119
P2120
P2121
ECM POWER SOURCE CIRCUIT
FUEL PUMP CONTROL CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT

SFI SYSTEM (2AZ-FSE) ( 2003.7 - )

PRECAUTION
LOCATION
HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
CHECK FOR INTERMITTENT PROBLEMS
BASIC INSPECTION
PROBLEM SYMPTOMS TABLE
TERMINALS OF ECM
DIAGNOSIS SYSTEM
DTC CHECK/CLEAR
CHECK MODE PROCEDURE
FAIL-SAFE CHART
DATA LIST/ACTIVE TEST
DIAGNOSTIC TROUBLE CODE CHART
P0010
P0011
P0016
P0031
P0100
P0105
P0110
P0115

P0116
P0120
P0121
P0130
P0133
P0134
P0136
P0171
P0190
P0191
P0200
P0230
P0300
P0325
P0335
P0340
P0351
P0420
P0443
P0500
P0504
P0505
P0555
P0556
P0560
P0604
P0617
P1235
P2008
P2102
P2111
P2118
P2119
P2120
P2121
ECM POWER SOURCE CIRCUIT
FUEL PUMP CONTROL CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT

ECD SYSTEM (1CD-FTV)

DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
PRECAUTION
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0045
P0087
P0088
P0093
P0095
P0100
P0101
P0105
P0106
P0110
P0115
P0116
P0168
P0180
P0191
P0200
P0234
P0335
P0340
P0380
P0400
P0488
P0500
P0504
P0560
P0606
P0622
P0627
P1238
P1271
P1601
P2120
P2121
P2226
P2227
ECM POWER SOURCE CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT

ECD SYSTEM (1CD-FTV) (From September, 2003)

PRECAUTION
LOCATION
SYSTEM DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
CHECK FOR INTERMITTENT PROBLEMS
BASIC INSPECTION
READING REGISTERED DATA
REGISTRATION
PROBLEM SYMPTOMS TABLE
TERMINALS OF ECM
DIAGNOSIS SYSTEM
DTC CHECK/CLEAR
CHECK MODE PROCEDURE
FAIL-SAFE CHART
DATA LIST/ACTIVE TEST
DIAGNOSTIC TROUBLE CODE CHART
P0031
P0045
P0087
P0088
P0093
P0095
P0100
P0101
P0105
P0106
P0110
P0115
P0116
P0120
P0168
P0180
P0191
P0200
P0234
P0335
P0340
P0380
P0400
P0405
P0488
P0500

P0504
P0544
P0560
P0606
P0622
P0627
P1238
P1271
P1386
P1425
P1426
P1601
P2002
P2047
P2120
P2121
P2226
P2227
P2237
ECM POWER SOURCE CIRCUIT
STARTER SIGNAL CIRCUIT
CHECK ENGINE WARNING LIGHT CIRCUIT
CLUTCH SWITCH CIRCUIT
DIFFICULT TO ENGINE START AND ENGINE STALL
BLACK SMOKE

ABS WITH EBD SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
C0200/31
C0210/33
C0226/21
C0273/13
C0278/11
C1237/37
C1241/41
C1249/58
C1300/62
C1350/51
AlwaysON
ABS WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
BRAKE WARNING LIGHT CIRCUIT
TC TERMINAL CIRCUIT
TS TERMINAL CIRCUIT

ABS WITH EBD & BA & TRC & VSC SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
C0200/31
C0210/33
C0226/21
C0273/13
C0278/11
C0365/43
C0371/55
C1201/45
C1224/44
C1203/59
C1208/54

C1225/25
C1237/37

C1241/41
C1246/53
C1249/58
C1288/88
C1300/62
C1301/42
C1350/51
AlwaysON
AlwaysON
ABS WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
VSC WARNING LIGHT CIRCUIT (DOES NOT LIGHT UP)
BRAKE WARNING LIGHT CIRCUIT

TRC OFF INDICATOR, TRC CUT SWITCH CIRCUIT
SLIP INDICATOR LIGHT CIRCUIT
SKID CONTROL BUZZER CIRCUIT
TC TERMINAL CIRCUIT
TS TERMINAL CIRCUIT

ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E(1AZ-FE))

HOW TO PROCEED WITH TROUBLESHOOTING
PRECAUTION
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0710/38
P0717/37
P0748/62
P0793/67
P2716/77
P2769/64
TRANSMISSION FLUID TEMPERATURE SENSOR NO.2 CIRCUIT
PARK / NEUTRAL POSITION SWITCH CIRCUIT
STOP LIGHT SWITCH SIGNAL CIRCUIT
KICK DOWN SWITCH CIRCUIT
TRANSMISSION CONTROL SWITCH CIRCUIT

ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U241E(1AZ-FSE))

HOW TO PROCEED WITH TROUBLESHOOTING
PRECAUTION
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0705
P0710
P0711
P0717
P0724
P0741
P0743
P0746
P0748
P0766
P0776
P0793
P2716
KICK DOWN SWITCH CIRCUIT
TRANSMISSION CONTROL SWITCH CIRCUIT
PATTERN SELECT SWITCH CIRCUIT

ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U341E)

HOW TO PROCEED WITH TROUBLESHOOTING
PRECAUTION
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0710
P0711
P0750
P0753
P0770
P0773
P1520
P1725
P1760
P1780
P1790
P1798
KICK DOWN SWITCH CIRCUIT
TRANSMISSION CONTROL SWITCH CIRCUIT
PATTERN SELECT SWITCH CIRCUIT

ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U341E)(From February, 2004)


HOW TO PROCEED WITH TROUBLESHOOTING
PRECAUTION
CUSTOMER PROBLEM ANALYSIS CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0705
P0710
P0711
P0717
P0724
P0741
P0751
P0756
P0787

P0973

P0976

P0998
P2716
P2769
TRANSMISSION CONTROL SWITCH CIRCUIT
PATTERN SELECT SWITCH CIRCUIT
KICK-DOWN SWITCH CIRCUIT
DEFINITION OF TERMS
PART AND SYSTEM NAME LIST
SYSTEM DIAGRAM
SYSTEM DESCRIPTION
ROAD TEST
MECHANICAL SYSTEM TESTS

HYDRAULIC TEST
MANUAL SHIFTING TEST
INITIALIZATION
MONITOR DRIVE PATTERN
DIAGNOSIS SYSTEM
DTC CHECK/CLEAR
CHECK MODE PROCEDURE
FAIL-SAFE CHART
DATA LIST/ACTIVE TEST

ELECTRONIC CONTROLLED AUTOMATIC TRANSAXLE [ECT] (U151E) ( 2003.7 - )

PRECAUTION
DEFINITION OF TERMS
LOCATION
SYSTEM DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
ROAD TEST
MECHANICAL SYSTEM TESTS
HYDRAULIC TEST
MANUAL SHIFTING TEST
INITIALIZATION
MONITOR DRIVE PATTERN
PROBLEM SYMPTOMS TABLE
TERMINALS OF ECM

DIAGNOSIS SYSTEM
DTC CHECK/CLEAR
CHECK MODE PROCEDURE
FAIL-SAFE CHART
DATA LIST/ACTIVE TEST
DIAGNOSTIC TROUBLE CODE CHART
P0705
P0710
P0711
P0717
P0724
P0741
P0743
P0746
P0748
P0766
P0771
P0776
P0778
P0793
P0796

P0798
P0982
P0985
P2716
TRANSMISSION CONTROL SWITCH CIRCUIT
PATTERN SELECT SWITCH CIRCUIT
KICK DOWN SWITCH CIRCUIT

ELECTRONIC MOTOR POWER STEERING SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
C1511/11
C1515/15
C1516/16
C1523/23
C1531/31
C1541/41
C1544/44
C1551/51
C1552/52
C1555/55
EMPS Warning Light Circuit
TC TERMINAL CIRCUIT
TS TERMINAL CIRCUIT

AIR CONDITIONING SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
11
12
13
21
23
24
31
33
36

41
43
46
BACK-UP POWER SOURCE CIRCUIT

IG POWER SOURCE CIRCUIT
HEATER RELAY CIRCUIT
BLOWER MOTOR CIRCUIT
AIR CONDITIONER MAGNETIC VALUE CIRCUIT
RECIRCULATION DAMPER SERVOMOTOR CIRCUIT
HOT GAS HEATER MAGNETIC VALUE CIRCUIT
HOT GAS HEATER SWITCH CIRCUIT

COMBUSTION TYPE POWER HEATER SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
ECU POWER SOURCE CIRCUIT
POWER HEATER SWITCH CIRCUIT
POWER HEATER FUEL PUMP CIRCUIT
POWER HEATER ALTERNATOR CIRCUIT

SUPPLEMENTAL RESTRAINT SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
B0100/13
B0101/14
B0102/11
B0103/12
B0105/53
B0106/54
B0107/51
B0108/52
B0110/43
B0111/44
B0112/41
B0113/42
B0115/47
B0116/48
B0117/45
B0118/46
B0121/26
B0126/27
B0130/63
B0131/64
B0132/61
B0133/62
B0135/73
B0136/74
B0137/71
B0138/72

B1100/31
B1140/32
B1141/33
B1148/36
B1149/37
B1153/25
B1154/38
B1155/39
B1160/83
B1161/84
B1162/81
B1163/82
B1165/87
B1166/88
B1167/85
B1168/86
B1180/17
B1181/18
B1182/19
B1183/22
B1185/57
B1186/58
B1187/55
B1188/56
B1650/49
SOURCE VOLTAGE DROP
SRS WARNING LIGHT CIRCUIT MALFUNCTION (ALWAYS LIGHT UP, WHEN IGNITION SWITCH IS ACC OR LOCK POSITION)
SRS WARNING LIGHT CIRCUIT MALFUNCTION (DOES NOT LIGHT UP, WHEN IGNITION SWITCH IS TURNED TO ON)
TC TERMINAL CIRCUIT

AUDIO SYSTEM

DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
POWER SOURCE CIRCUIT (RADIO RECEIVER ASSY)
SOUND QUALITY IS BAD IN ALL MODES (VOLUME IS TOO LOW)
NOISE OCCURS
RADIO BROADCAST CANNOT BE RECEIVED (BAD RECEPTION)
CD CANNOT BE INSERTED OR IS EJECTED RIGHT AFTER INSERTION
CD CANNOT BE EJECTED
SOUND QUALITY IS BAD ONLY WHEN CD IS PLAYED (VOLUME IS TOO LOW)
CD SOUND SKIPS
CASSETTE TAPE CANNOT BE INSERTED OR PLAYED
CASSETTE TAPE CANNOT BE EJECTED
SOUND QUALITY IS BAD ONLY WHEN PLAYING TAPE
TAPE IS TANGLED DUE TO INCORRECT TAPE SPEED OR AUTO-REVERSE MALFUNCTION
A AUDIO SYSTEM CANNOT BE OPERATED WITH STEERING PAD SWITCH


NAVIGATION SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
POWER SOURCE CIRCUIT (MULTI-DISPLAY (CRT DISPLAY) DISPLAY)
POWER SOURCE CIRCUIT (NAVIGATION ECU)
POWER SOURCE CIRCUIT (NAVIGATION CONTROLLER HOLDER)
AVC-LAN CIRCUIT
NAVIGATION SCREEN NOT STABILIZED (SYNCHRONOUS ERROR)
COLOR ON NAVIGATION SCREEN IS UNUSUAL (RGB SIGNAL ERROR)
FRONT SPEAKER (DRIVER SIDE) ONLY IS NOT HEARD
CURRENT POSITION CANNOT BE DISPLAYED ON SCREEN (DISC CAUTION SCREEN DOES NOT CHANGE)
MAP IS DISPLAYED IN WHITE OR BLUE SCREEN (SWITCHED AND VEHICLE POSITION MARK ARE DISPLAYED)
VEHICLE POSITION IS DEVIATED FROM CORRECT POINT BADLY
GPS MARK DOES NOT APPEAR
VEHICLE POSITION MARK ROTATES ARBITRARILY (MAP ROTATES ARBITRARILY)
DRIVING DIRECTIONS OPPOSITE TO MOVING DIRECTION OF VEHICLE POSITION MARK
A NAVIGATION CONTROLLER ASSY DOES NOT OPERATE
WHEN MOUNT THE NAVIGATION CONTROLLER ASSY TO THE NAVIGATION CONTROLLER HOLDER, IT CANNOT BE OPERATED
THE SYSTEM CANNOT BE OPERATED BY THE VOICE SOUND

COMBINATION METER

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
MALFUNCTION IN SPEEDOMETER
MALFUNCTION IN TACHOMETER
MALFUNCTION IN WATER TEMPERATURE RECEIVER GAUGE
MALFUNCTION IN FUEL RECEIVER GAUGE
ENTIRE COMBINATION METER DOES NOT OPERATE
SEAT BELT WARNING LAMP FOR DRIVER?S SEAT DOES NOT OPERATE
SEAT BELT WARNING LAMP FOR FRONT PASSENGER?S SEAT DOES NOT FLASH
THE AMBIENT TEMPERATURE DOES NOT DISPLAY
WARNING BUZZER DOES NOT SOUND

POWER DOOR LOCK CONTROL SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
CUSTOMIZE PARAMETERS
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
ALL DOORS CANNOT BE LOCKED / UNLOCKED AT ONCE
KEY LOCK-IN PREVENTION FUNCTION DOES NOT WORK PROPERLY (MANUAL OPERATION AND OPERATION INTERLOCKED WITH KEY ARE ACTIVE)
DOUBLE LOCK FUNCTION DOES NOT OPERATE PROPERLY

WIRELESS DOOR LOCK CONTROL SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
ONLY WIRELESS CONTROL FUNCTION DOES NOT OPERATE (PREPARE NEW OR NORMAL TRANSMITTER OF THE SAME TYPE VEHICLE)
NO ANSWER-BACK (HAZARD WARNING LAMP)

KEY REMINDER WARNING SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
KEY REMINDER BUZZER DOES NOT SOUND

ENGINE IMMOBILISER SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
B2780
B2784
B2793
B2794
B2795
B2796
B2797
B2799

THEFT DETERRENT SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
LOCATION
TERMINALS OF ECU
PROBLEM SYMPTOMS TABLE
SECURITY INDICATOR CIRCUIT
ECU POWER SOURCE CIRCUIT
IGNITION SWITCH CIRCUIT
ENGINE HOOD COURTESY SWITCH CIRCUIT
HORN CIRCUIT
THEFT WARNING SIREN CIRCUIT
INTRUSION SENSOR CIRCUIT

MULTIPLEX COMMUNICATION SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECU

B1214
B1261
B1262
B1269
B1271

CRUISE CONTROL SYSTEM

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK
PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0500/21
P0571/52
P0607/54
CRUISE CONTROL SWITCH CIRCUIT
CRUISE MAIN INDICATOR LIGHT CIRCUIT
DIAGNOSIS CIRCUIT

CRUISE CONTROL SYSTEM (2AZ-FSE)(From February, 2004)

HOW TO PROCEED WITH TROUBLESHOOTING
CUSTOMER PROBLEM ANALYSIS CHECK

PRE-CHECK
DIAGNOSTIC TROUBLE CODE CHART
LOCATION
TERMINALS OF ECM
PROBLEM SYMPTOMS TABLE
P0500/21
P0571/52
P0607/54
CRUISE CONTROL SWITCH CIRCUIT
CRUISE MAIN INDICATOR LIGHT CIRCUIT
DIAGNOSIS CIRCUIT

ENGINE CONTROL SYSTEM

SFI SYSTEM (1ZZ-FE/3ZZ-FE)


ON-VEHICLE INSPECTION
INSPECTION

SFI SYSTEM (1ZZ-FE/3ZZ-FE)(From February, 2004)

ON-VEHICLE INSPECTION
INSPECTION

THROTTLE BODY ASSY (1ZZ-FE)

COMPONENTS
Removal & Installation and Disassembly & Reassembly

THROTTLE BODY ASSY (3ZZ-FE)

COMPONENTS
Removal & Installation and Disassembly & Reassembly

THROTTLE BODY ASSY (1ZZ-FE/3ZZ-FE)(From February, 2004)

COMPONENTS
REPLACEMENT

KNOCK SENSOR (1ZZ-FE/3ZZ-FE)

REPLACEMENT

ACCELERATOR PEDAL ASSY (1ZZ-FE/3ZZ-FE)(From February, 2004)

REPLACEMENT


SFI SYSTEM (1AZ-FE)

ON-VEHICLE INSPECTION
INSPECTION

THROTTLE BODY ASSY (1AZ-FE)

COMPONENTS
Removal & Installation and Disassembly & Reassembly

KNOCK SENSOR (1AZ-FE)

COMPONENTS
REPLACEMENT

SFI SYSTEM (1AZ-FSE)

ON-VEHICLE INSPECTION
INSPECTION

THROTTLE BODY ASSY (1AZ-FSE)

COMPONENTS
REPLACEMENT

KNOCK SENSOR (1AZ-FSE)

COMPONENTS
REPLACEMENT

SFI SYSTEM (2AZ-FSE) ( 2003.7 - )

ON-VEHICLE INSPECTION
INSPECTION

THROTTLE BODY ASSY (2AZ-FSE) ( 2003.7 - )

COMPONENTS
REPLACEMENT

KNOCK SENSOR (2AZ-FSE) ( 2003.7 - )

COMPONENTS
REPLACEMENT

ACCELERATOR PEDAL ASSY (2AZ-FSE) ( 2003.7 - )

REPLACEMENT

ECD SYSTEM (1CD-FTV)

ON-VEHICLE INSPECTION
INSPECTION

ECD SYSTEM (1CD-FTV)(From September, 2003)

ON-VEHICLE INSPECTION
INSPECTION

INTAKE SHUTTER ASSY (1CD-FTV)

COMPONENTS
Removal & Installation and Disassembly & Reassembly

INTAKE SHUTTER ASSY (1CD-FTV)(From September, 2003)

COMPONENTS
Removal & Installation and Disassembly & Reassembly

CAMSHAFT POSITION SENSOR (1CD-FTV)

REPLACEMENT

CRANKSHAFT POSITION SENSOR (1CD-FTV)

REPLACEMENT

ECM

REPLACEMENT

ECM(From September, 2003)

REPLACEMENT

ACCELERATOR PEDAL ASSY (1AZ-FSE/1CD-FTV)


REPLACEMENT

FUEL

FUEL SYSTEM (1ZZ-FE/3ZZ-FE)

PRECAUTION
ON-VEHICLE INSPECTION
INSPECTION

FUEL INJECTOR ASSY (1ZZ-FE/3ZZ-FE)

COMPONENTS
REPLACEMENT

FUEL SYSTEM (1AZ-FE)

PRECAUTION
ON-VEHICLE INSPECTION
INSPECTION

FUEL INJECTOR ASSY (1AZ-FE)

COMPONENTS
REPLACEMENT

FUEL PRESSURE PULSATION DAMPER ASSY (1AZ-FE)

REPLACEMENT

FUEL SYSTEM(1AZ-FSE)

PRECAUTION
ON-VEHICLE INSPECTION
INSPECTION

FUEL INJECTOR ASSY (1AZ-FSE)

COMPONENTS
REPLACEMENT

FUEL PUMP ASSY (1AZ-FSE)

COMPONENTS
REPLACEMENT


FUEL SYSTEM (2AZ-FSE) ( 2003.7 - )

PRECAUTION
ON-VEHICLE INSPECTION
INSPECTION

FUEL INJECTOR ASSY (2AZ-FSE) ( 2003.7 - )

COMPONENTS
REPLACEMENT

FUEL PUMP ASSY (2AZ-FSE) ( 2003.7 - )

COMPONENTS
REPLACEMENT

FUEL SUCTION W/ PUMP & GAUGE TUBE ASSY (2AZ-FSE) ( 2003.7 - )

COMPONENTS
REPLACEMENT

FUEL TANK ASSY (2AZ-FSE) ( 2003.7 - )

COMPONENTS
Removal & Installation and Disassembly & Reassembly

FUEL SYSTEM (1CD-FTV)

INSPECTION

FUEL SYSTEM (1CD-FTV)(From September, 2003)

INSPECTION

INJECTOR ASSY (1CD-FTV)

COMPONENTS
REPLACEMENT

INJECTOR ASSY (1CD-FTV)(From September, 2003)

COMPONENTS
REPLACEMENT

INJECTION OR SUPPLY PUMP ASSY (1CD-FTV)

COMPONENTS
REPLACEMENT

INJECTION OR SUPPLY PUMP ASSY (1CD-FTV)(From September, 2003)

COMPONENTS
REPLACEMENT

COMMON RAIL ASSY (1CD-FTV)

COMPONENTS
REPLACEMENT

COMMON RAIL ASSY (1CD-FTV)(From September, 2003)

COMPONENTS
REPLACEMENT


FUEL FILTER ASSY (1CD-FTV)

REPLACEMENT

FUEL PUMP ASSY (GASOLINE)

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