Toyota Celica 2005 Repair Manual Download Page 933

Page: 933 / 2497

D13056

ECM

SL1

−

SL2

−

E11

−

Shift Solenoid Valve SL2

Shift Solenoid Valve S4

Shift Solenoid Valve SL1

Automatic Transaxle

E11

SL1+

SL1

−

SL2

−

732

−

DIAGNOSTICS

AUTOMATIC TRANSAXLE (U240E)

2005 CELICA (RM1131U)

WIRING DIAGRAM

932

Summary of Contents for Celica 2005

Page 1: ...ICS ENGINE MECHANICAL EMISSION CONTROL SFI COOLING LUBRICATION IGNITION STARTING CHARGING CLUTCH MANUAL TRANSAXLE C56 MANUAL TRANSAXLE C60 AUTOMATIC TRANSAXLE U240E AUTOMATIC TRANSAXLE U341E SUSPENSION AND AXLE BRAKE STEERING SUPPLEMENTAL RESTRAINT SY STEM SRS BODY ELECTRICAL BODY AIR CONDITIONING 2005 CELICA REPAIR MANUAL 2005 CELICA RM1131U ...

Page 2: ... each section a PRECAUTION is given that pertains to all repair operations contained in that section Read these precautions before starting any repair task 3 TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause The fundamentals of how to proceed with troubleshooting are described on page IN 20 Be sure to read this before performing...

Page 3: ...ad 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 t...

Page 4: ...AND ENGINE SERIAL NUMBER 1 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and the certification label as shown in the illustration A Vehicle Identification Number Plate B Certification Label 2 ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown in the illustration 3 ...

Page 5: ...with a clean shop rag Do not scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals after loosening the nut and tighten the nut after installa tion Do not use a hammer to tap the cable ends onto the terminals 6 Be sure the cover for the positive terminal is properly in place d Check hose and wiring connectors to make sure that they are connected secure...

Page 6: ...hen 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 Preparat...

Page 7: ...ed 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 l Observe the following precautions to avoid damage to the following parts 1 Do not open the cover or case of the ECU unless absolutely necessary If the IC terminals are touched the IC may be destroyed by static electric ity 2 To ...

Page 8: ...eak air m Installation and removal of vacuum hose 1 When disconnecting vacuum hoses use tags to identify how 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 n Unless otherwise stated all resistance is measured at an ambient temperature of 20 C 68 F Because the resis tance may be outside...

Page 9: ...SITION SUPPORT POSITION Safety stand and swing arm type lift When jacking up the rear and front make sure the car is not carrying any extra weight Front crossmember Rear axle beam IN 8 INTRODUCTION REPAIR INSTRUCTIONS 2005 CELICA RM1131U VEHICLE LIFT AND SUPPORT LOCATIONS 8 ...

Page 10: ...e over the center of the lift S Align the cushion gum ends of the plate with the attachment lower ends A C S Align the attachment upper end B with the front jack supporting point L Attachment dimensions 85 mm 3 35 in 100 mm 3 94 in 70 mm 2 76 in 200 mm 7 87 in INTRODUCTION REPAIR INSTRUCTIONS IN 9 2005 CELICA RM1131U 9 ...

Page 11: ...alfunction 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 page DI 884 2 Work must be started after 90 seconds from the time the ignition ...

Page 12: ...as sembly or seat belt pretensioner has been dropped or if there are cracks dents or other defects in the case bracket or connector replace them with new ones 8 Do not directly expose the airbag sensor assembly steering wheel pad front passenger airbag assem bly side airbag assembly or seat belt pretensioner to hot air or flames 9 Use a volt ohmmeter with high impedance 10 kΩ V minimum for trouble...

Page 13: ...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...

Page 14: ...bag 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 an...

Page 15: ...g 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 th...

Page 16: ...re 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 page BO 112 Per form the operation in a safe place away...

Page 17: ...ause 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 harnes...

Page 18: ...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 fa...

Page 19: ...TOYOTA hand held tester s operator manual should be read thoroughly S Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand held tester connected to the vehicle i e Keep cables away from feet pedals steering wheel and shift lever S Two persons are required when test driving with the OBD II scan tool or TOYOTA hand held tester one person to drive the vehicle and...

Page 20: ...wing pages System Page 1 1ZZ FE Engine DI 1 2 2ZZ GE Engine DI 293 3 U240E Automatic Transaxle DI 666 4 U341E Automatic Transaxle DI 755 5 Anti Lock Brake System with Electronic Brake Force Distribution EBD DI 834 6 Supplemental Restraint System DI 882 7 Cruise Control System 1ZZ FE DI 1037 8 Cruise Control System 2ZZ GE DI 1088 9 Body Control system DI 1117 FOR USING OBD II SCAN TOOL OR TOYOTA HA...

Page 21: ... should be checked using the diagnostic trouble code chart or the problem symptoms table 4 5 6 Check and repair the affected system or part in accordance with the instructions in Step 6 7 After completing repairs confirm that the problem has been eliminated If the problem is not reproduced perform the confirmation test under the same conditions and in the same environment as when it occurred for t...

Page 22: ...ssed After accelerator pedal released During A C operation Shifting from N to D Other Data Problem Constant Sometimes times per day month Inspector s Name CUSTOMER PROBLEM ANALYSIS CHECK INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN 21 2005 CELICA RM1131U 1 CUSTOMER PROBLEM ANALYSIS In troubleshooting the problem symptoms must be confirmed accurately and all preconceptions must be cle...

Page 23: ...he Input Signal Check which checks if the signals from various switches are sent to the ECU correctly By using these check functions the problem areas can be narrowed down quickly and troubleshooting can be performed effectively Diagnostic functions are incorporated in the following systems in the CELICA System Diagnostic Trouble Code Check Input Signal Check Sensor Check Diagnostic Test Mode Acti...

Page 24: ...nostic trouble code was displayed in the initial diagnostic trouble code check it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past Therefore check the wire harness and con nectors See page IN 30 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN 23 2005 CELICA RM1131U Taking into account the points on the previous page a flow chart sho...

Page 25: ... problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere which will only lead to a standstill For example for a problem which only occurs when the en gine is cold or for a problem which occurs due to vibration caused by the road during driving etc the prob lem can never be determined so long as the symptoms are confirmed with the engin...

Page 26: ...e heater blower head lights rear window defogger etc and check to see if the mal function occurs ON HINT If a vehicle is subject to water leakage the leaked water may contaminate the ECU When testing a vehicle with a water leak age problem special caution must be taken M a l f u n c tion Do not heat to more than 60 C 140 F Temperature is limited not to damage the components Do not apply heat direc...

Page 27: ...eters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors If a malfunction code is displayed during the DTC check mode check the circuit for that code listed in the table below For details of each code turn to the page referred to under the See page for the respective DTC No in the DTC chart Mass Air Flow Circuit Range Performance Problem ...

Page 28: ...Does not start 1 Starter and starter relay 1 ECM power source circuit 2 Fuel pump control circuit 3 Engine control module ECM 1 Starter signal circuit 2 Fuel pump control circuit 1 Fuel pump control circuit DI 147 DI 151 IN 29 PROBLEM SYMPTOMS TABLE 1 Compression 2 Fuel pump control circuit 1 A C signal circuit 2 Fuel pump control circuit 1 A C signal circuit Compressor circuit 2 ECM power source ...

Page 29: ...formed which occurs when the cylinder block vibrates due to knocking If engine knocking occurs ignition timing is retarded to suppress it DTC No DTC Detecting Condition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed 1 200 rpm or more D Open or short in knock sensor1 circuit D Knock sensor 1 looseness D ECM If the ECM detects the above diagnosis conditions it operates the fall...

Page 30: ...connector back side with harness Ignition Switch LOCK OFF Ignition Switch START LOCK Ignition Switch ON Ignition Switch ACC START ON ACC D D Indicates the place to check the voltage or resistance D Indicates the connector position to checked from the front or back side Connector being checked is disconnected Check from the connector front side without harness In this case care must be taken not to...

Page 31: ...es Follow the procedure outlined below whenever these instructions appear OPEN CIRCUIT This could be due to a disconnected wire harness faulty con tact in the connector a connector terminal pulled out etc HINT S It is rarely the case that a wire is broken in the middle of it Most cases occur at the connector In particular care fully check the connectors of sensors and actuators S Faulty contact co...

Page 32: ...s of the connectors Resistance 1 Ω or less HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally 4 RESISTANCE CHECK SHORT CIRCUIT CHECK a Disconnect the connectors on both ends b Measure the resistance between the applicable terminals of the connectors and body ground Be sure to carry out this check on the connectors on both ends Resistance 1 MΩ or higher H...

Page 33: ...b Voltage Check to locate the section a Check the continuity 1 Disconnect connectors A and C and measure the resistance between them In the case of Fig 2 Between terminal 1 of connector A and terminal 1 of connector C No continuity open Between terminal 2 of connector A and terminal 2 of connector C Continuity Therefore it is found out that there is an open circuit between terminal 1 of connector ...

Page 34: ...n Terminal 1 of connector A and Body Ground 5V Between Terminal 1 of connector B and Body Ground 0V Between Terminal 1 of connector C and Body Ground Then it is found out that there is an open circuit in the wire har ness between terminal 1 of B and terminal 1 of C 7 CHECK SHORT CIRCUIT If the wire harness is ground shorted as in Fig 5 locate the sec tion by conducting a continuity check with grou...

Page 35: ...n terminal 1 of connector B2 and body ground Continuity short Therefore it is found out that there is a short circuit between terminal 1 of connector B2 and terminal 1 of connector C 8 CHECK AND REPLACE ECU First check the ECU ground circuit If it is faulty repair it If it is normal the ECU could be faulty so replace the ECU with a nor mal functioning one and check that the symptoms appear 1 Measu...

Page 36: ...tely A T Automatic Transmission Transaxle ATF Automatic Transmission Fluid AUTO Automatic AUX Auxiliary AVG Average AVS Adaptive Variable Suspension BA Brake Assist BACS Boost Altitude Compensation System BAT Battery BDC Bottom Dead Center B L Bi Level B S Bore Stroke Ratio BTDC Before Top Dead Center BVSV Bimetallic Vacuum Switching Valve Calif California CB Circuit Breaker CCo Catalytic Converte...

Page 37: ...osited Coating EDIC Electric Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection E G Engine EGR VM Exhaust Gas Recirculation Vacuum Modulator ELR Emergency Locking Retractor ENG Engine ESA Electronic Spark Advance ETCS Electronic Throttle Control System EVP Evaporator E VRV Electric Vacuum Regulating Valve EXH Exhaust FE Fuel Economy FF Front Engine Front Wheel Drive...

Page 38: ...nt Rear Suspension J B Junction Block J C Junction Connector KD Kick Down LAN Local Area Network LB Liftback LCD Liquid Crystal Display LED Light Emitting Diode LH Left Hand LHD Left Hand Drive L H W Length Height Width LLC Long Life Coolant LNG Liquified Natural Gas LO Low LPG Liquified Petroleum Gas LSD Limited Slip Differential LSP PV Load Sensing Proportioning And Bypass Valve LSPV Load Sensin...

Page 39: ... Type Steering R F Reinforcement RFS Rigid Front Suspension RH Right Hand RHD Right Hand Drive RLY Relay ROM Read Only Memory Rr Rear RR Rear Engine Rear Wheel Drive RRS Rigid Rear Suspension RWD Rear Wheel Drive SDN Sedan SEN Sensor SICS Starting Injection Control System SMT Sequential Manual Transmission SOC State Of Charge SOHC Single Overhead Camshaft SPEC Specification SPI Single Point Inject...

Page 40: ...ion TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky Inc TRAC Traction Control System TURBO Turbocharger U D Underdrive U S Undersize VCV Vacuum Control Valve VENT Ventilator VIN Vehicle Identification Number VPS Variable Power Steering VSC Vehicle Skid Control VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve w With WGN Wagon W H Wire Harness w o Without 1st First 2nd ...

Page 41: ...Connector 2 Data Link Connector 3 1 Check Connector 2 Total Diagnosis Comunication Link TDCL 3 OBD II Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode ECL Engine Control Level ECM Engine Control Module Engine ECU Electronic Control Unit ECT Engine Coolant Temperature Coolant Temperature Water Temperature THW EEPROM Electrically Erasable Programmable Read On...

Page 42: ... Oxygen Sensor Oxygen Sensor O2 Sensor O2S OBD On Board Diagnostic On Board Diagnostic System OBD OC Oxidation Catalytic Converter Oxidation Catalyst Convert OC CCo OP Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction AS PCM Powertrain Control Module PNP Park Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer Diesel Particu...

Page 43: ...acuum Switching Valve TVSV TWC Three Way Catalytic Converter Three Way Catalytic TWC Manifold Converter CCRO TWC OC Three Way Oxidation Catalytic Converter CCR CCo VAF Volume Air Flow Air Flow Meter VR Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor WOT Wide Open Throttle Full Throttle WU OC Warm Up Oxidation Catalytic Converter WU TWC Warm Up Three Way Catalytic ...

Page 44: ...irst the odometer reading miles or the time interval months S Maintenance service after the last period should be performed at the same interval as before unless otherwise noted S Failure to do even one item cause the engine to run poorly and increase exhaust emissions 2 TIRES a Check the pressure with a gauge If necessary adjust b Check for cuts damage or excessive wear 3 WHEEL NUTS When checking...

Page 45: ...en one item cause the engine to run poorly and increase exhaust emissions 2 LIGHTS a Check that the headlights stop lights taillights turn signal lights and other lights are all working b Check the headlight aim 3 WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly 4 HORN Check that it is working 5 WINDSHIELD GLASS Check for scratches pits or abrasions 6 WINDSHIE...

Page 46: ...eserve distance and free play c Check the brake booster function 16 BRAKES At a safe place check that the brakes do not pull to one side when applied 17 PARKING BRAKE See page BR 9 a Check that the lever has the proper travel b On a safe incline check that the vehicle is held securely with only the parking brake applied 18 AUTOMATIC TRANSMISSION PARK MECHANISM a Check the lock release button of th...

Page 47: ...RY ELECTROLYTE LEVEL Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case 6 BRAKE AND CLUTCH FLUID LEVELS Check that the brake and clutch fluid levels are near the upper level line on the see through reservoirs 7 ENGINE DRIVE BELTS Check drive belt for fraying cracks wear or oiliness 8 ENGINE OIL LEVEL Check the level on the dipstick with the...

Page 48: ... that the air filter is not excessively dirty or oily HINT Oiliness may indicate a stuck PCV valve If necessary replace the air cleaner element 4 REPLACE ENGINE OIL AND OIL FILTER See page LU 3 5 REPLACE ENGINE COOLANT See page CO 2 6 REPLACE GASKET IN FUEL TANK CAP See page SF 28 7 INSPECT FUEL LINES AND CONNECTIONS See page SF 28 8 INSPECT EXHAUST PIPES AND MOUNTINGS See page EC 11 9 ADJUST VALV...

Page 49: ... a Check all brake lines and hoses for S Damage S Wear S Deformation S Cracks S Corrosion S Leaks S Bends S Twists b Check all clamps for tightness and connections for leak age c Check that the hoses and lines are clear of sharp edges moving parts and the exhaust system d Check that the lines installed in grommets pass through the center of the grommets 2 INSPECT FRONT BRAKE PADS AND DISCS See pag...

Page 50: ...the drive shaft boots for clamp looseness leakage or damage 4 INSPECT BALL JOINT AND DUST COVERS a Inspect the ball joints for excessive looseness S Jack up the front of the vehicle and place wooden blocks with a height of 180 200 mm 7 09 7 87 in under the front tires S Lower the jack until there is about half a load on the front coil spring Place stands under the vehicle for safety S Check that t...

Page 51: ...341E See page DI 758 7 TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY If the vehicle is mainly operated under the rough muddy road conditions Tighten the seat mounting bolts and front and rear suspension member retaining bolts to specified torque S Seat mounting bolts Torque 37 N m 375 kgf cm 27 ft lbf S Front suspension member to body mounting bolts Torque Bolt A 113 N m 1 152 kgf cm 83 ft lbf Bolt B...

Page 52: ...PP0E6 08 PREPARATION MAINTENANCE PP 1 2005 CELICA RM1131U MAINTENANCE EQUIPMENT Mirror Brake hose Torque wrench 51 ...

Page 53: ... Re placer 5 5 09201 41020 Valve Stem Oil Seal Replacer 09202 70020 Valve Spring Compressor 09202 00020 Attachment 09222 30010 Connecting Rod Bushing Remover Replacer 09223 15030 Oil Seal Bearing Replacer 09223 22010 Crankshaft Front Oil Seal Replacer 09309 37010 Transmission Bearing Replacer 09816 30010 Oil Pressure Switch Socket 09950 70010 Handle Set 09951 07100 Handle 100 52 ...

Page 54: ... PREPARATION ENGINE MECHANICAL PP 3 2005 CELICA RM1131U 09960 10010 Variable Pin Wrench Set 09962 01000 Variable Pin Wrench Arm Assy 09963 01000 Pin 10 53 ...

Page 55: ...PREPARATION ENGINE MECHANICAL 2005 CELICA RM1131U RECOMMENDED TOOLS 09090 04020 Engine Sling Device For suspending engine 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc 54 ...

Page 56: ...ston ring groove Heater Magnetic finger Micrometer OBDII scan tool Pin hole grinder Piston pin hole of piston Piston ring compressor Piston ring expander Plastigage Precision straight edge Press Ridge reamer Cylinder Soft brush Solvent Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Torx wrench socket set Stud bolt Valve seat cutter V block Vernier calipers Wire brus...

Page 57: ...ECHANICAL 2005 CELICA RM1131U SSM Special Service Materials 08826 00080 Seal Packing Black or equivalent FIPG 08826 00100 Seal Packing 1282B THREE BOND 1282B or equivalent FIPG 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent 56 ...

Page 58: ...PP419 02 PREPARATION EMISSION CONTROL PP 7 2005 CELICA RM1131U EMISSION CONTROL RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 57 ...

Page 59: ...PP0JV 16 PP 8 PREPARATION EMISSION CONTROL 2005 CELICA RM1131U EQUIPMENT Torque wrench Vacuum gauge Pressure gauge Hose clipper 58 ...

Page 60: ... 09268 41047 Injection Measuring Tool Set 95336 08070 Hose 09268 41250 T Joint 09268 45014 EFI Fuel Pressure Gauge 09268 41200 Gauge 09268 41220 Hose 09268 41250 T Joint 09816 30010 Oil Pressure Switch Socket Knock sensor for 1ZZ GE engine 09842 30080 EFI Inspection Wire H 09843 18020 Diagnosis Check Wire 59 ...

Page 61: ...PP0JX 08 PP 10 PREPARATION SFI 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09258 00030 Hose Plug Set Plug for vacuum hose fuel hose etc 60 ...

Page 62: ...19 PREPARATION SFI PP 11 2005 CELICA RM1131U EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBDII scan tool Soft brush Throttle body Sound scope Injector Torque wrench Vacuum gauge 61 ...

Page 63: ...RATION COOLING 2005 CELICA RM1131U COOLING SST Special Service Tools 09230 01010 Radiator Service Tool Set 09231 14010 Punch 09960 10010 Variable Pin Wrench Set 09962 01000 Variable Pin Wrench Arm Assy 09963 00600 Pin 6 62 ...

Page 64: ...PP189 10 PREPARATION COOLING PP 13 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 63 ...

Page 65: ...PP18A 12 PP 14 PREPARATION COOLING 2005 CELICA RM1131U EQUIPMENT Heater ECT switch Thermostat Radiator cap tester Thermometer ECT switch Thermostat Torque wrench Vernier calipers 64 ...

Page 66: ...RM1131U COOLANT Item Capacity Classification Engine coolant 1ZZ FE M T A T 2ZZ GE M T A T 5 7 liters 6 0 US qts 5 0 lmp qts 5 6 liters 5 9 US qts 4 9 lmp qts 5 9 liters 6 2 US qts 5 2 lmp qts 5 8 liters 6 1 US qts 5 1 lmp qts Ethylene glycol base 65 ...

Page 67: ...PP2DU 05 PP 16 PREPARATION LUBRICATION 2005 CELICA RM1131U LUBRICATION SST Special Service Tools 09228 06501 Oil Filter Wrench 09816 30010 Oil Pressure Switch Socket 66 ...

Page 68: ...PP0K5 15 PREPARATION LUBRICATION PP 17 2005 CELICA RM1131U EQUIPMENT Oil pressure gauge Torque wrench Feeler gauge Straight edge 67 ...

Page 69: ...Oil Filter change 2ZZ GE w Oil Filter change w o Oil Filter change Dry fill 1ZZ FE 2ZZ GE 3 7 liters 3 9 US qts 3 3 lmp qts 3 5 liters 3 7 US qts 3 1 lmp qts 4 4 liters 4 8 US qts 4 0 lmp qts 4 2 liters 4 6 US qts 3 8 lmp qts 4 2 liters 4 4 US qts 3 7 lmp qts 4 8 liters 5 1 US qts 4 2 lmp qts API grade SL Energy Conserving or ILSAC mul tigrade engine oil 68 ...

Page 70: ...PP2DT 06 PREPARATION LUBRICATION PP 19 2005 CELICA RM1131U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent Oil pressure switch 69 ...

Page 71: ...PP0K8 18 PP 20 PREPARATION IGNITION 2005 CELICA RM1131U IGNITION RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit 70 ...

Page 72: ...PP0K9 10 PREPARATION IGNITION PP 21 2005 CELICA RM1131U EQUIPMENT Spark plug cleaner 71 ...

Page 73: ...REPARATION STARTING 2005 CELICA RM1131U STARTING SST Special Service Tools 09286 46011 Injection Pump Spline Shaft Puller 09810 38140 Starter Magnet Switch Nut Wrench 14 09820 00031 Alternator Rear Bearing Replacer 72 ...

Page 74: ...PP0KB 11 PREPARATION STARTING PP 23 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 73 ...

Page 75: ...2005 CELICA RM1131U EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit part Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commutator Vernier calipers Commutator Brush 74 ...

Page 76: ... Bearing Cone Replacer 09286 46011 Injection Pump Spline Shaft Puller 09820 00021 Alternator Rear Bearing Puller 09820 00031 Alternator Rear Bearing Replacer 09820 63011 Alternator Pulley Set Nut Wrench Set 09950 60010 Replacer Set 09951 00350 Replacer 35 09951 00530 Replacer 53 09950 70010 Handle Set 09951 07100 Handle 100 75 ...

Page 77: ...PP0KE 11 PP 26 PREPARATION CHARGING 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 76 ...

Page 78: ...P0KF 11 PREPARATION CHARGING PP 27 2005 CELICA RM1131U EQUIPMENT Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor Slip ring Brush 77 ...

Page 79: ...Z 06 PP 28 PREPARATION CLUTCH 2005 CELICA RM1131U CLUTCH SST Special Service Tools 09023 00101 Union Nut Wrench 10mm Clutch line 09301 00210 Clutch Guide Tool 09333 00013 Clutch Diaphragm Spring Aligner 78 ...

Page 80: ...PP2E1 03 PREPARATION CLUTCH PP 29 2005 CELICA RM1131U RECOMMENDED TOOLS 09031 00030 Pin Punch 09082 00040 TOYOTA Electrical Tester 09905 00013 Snap Ring Pliers 79 ...

Page 81: ...PP0H1 05 PP 30 PREPARATION CLUTCH 2005 CELICA RM1131U EQUIPMENT Vernier calipers Dial indicator Torque wrench 80 ...

Page 82: ...PP0CK 14 PREPARATION CLUTCH PP 31 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT3 81 ...

Page 83: ...Replacer 09316 60011 Transmission Transfer Bearing Replacer Differential tapered roller bearing 09316 00011 Replacer Pipe 09350 32014 TOYOTA Automatic Transmission Tool Set Differential tapered roller bearing 09351 32120 Overdrive Bearing Replacer 09351 32140 Oil Seal Replacer 09564 32011 Differential Preload Adaptor 09608 00071 Drive Pinion Rear Bearing Cone Replacer Input shaft rear radial ball ...

Page 84: ...ushing Replacer 09950 00020 Bearing Remover 09950 00030 Bearing Remover Attachment Differential tapered roller bearing 09950 30012 Puller A Set No 3 clutch hub 09950 40011 Puller B Set 5th driven gear 09950 60010 Replacer Set 09951 00230 Replacer 23 5th driven gear 09951 00350 Replacer 35 Differential tapered roller bearing 09951 00360 Replacer 36 Input shaft front oil seal Differential tapered ro...

Page 85: ...put shaft front bearing 09950 60020 Replacer Set No 2 09951 00680 Replacer 68 Differential tapered roller bearing outer race Transaxle case side 09951 00710 Replacer 71 Differential tapered roller bearing outer race Transmission case side 09950 70010 Handle Set 09951 07150 Handle 150 84 ...

Page 86: ...ECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgf cm Differential preload 09031 00030 Pin Punch 09040 00011 Hexagon Wrench Set 09042 00010 Torx Socket T30 09090 04020 Engine Sling Device 09905 00012 Snap Ring No 1 Expander Torx is a registered trademark of Textron Inc 85 ...

Page 87: ...PP04Q 08 PP 36 PREPARATION MANUAL TRANSAXLE C56 2005 CELICA RM1131U EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Magnetic finger Wooden block or similar object 86 ...

Page 88: ... 10 PREPARATION MANUAL TRANSAXLE C56 PP 37 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Manual transaxle oil w Differential oil 1 9 liters 2 0 US qts 1 7 lmp qts API GL 4 or GL 5 SAE 75W 90 87 ...

Page 89: ...LICA RM1131U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG Transmission case x Transaxle case Transmission case x Transmission case cover 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 88 ...

Page 90: ...tapered roller bearing 09316 00011 Replacer Pipe 09325 12010 Transmission Oil Plug Input shaft rear radial ball bearing 6th driven gear 09350 32014 TOYOTA Automatic Transmission Tool Set Differential case tapered roller bearing 09351 32120 Overdrive Bearing Replacer 09351 32140 Oil Seal Replacer 09517 12010 Rear Axle Shaft Oil Seal Replacer Output shaft rear radial ball bearing Input shaft rear ra...

Page 91: ...aft front bearing Differential tapered roller bearing outer race 09710 28021 Front Suspension Bushing Tool Set Transaxle case oil seal 09710 08041 Bushing Replacer 09950 00020 Bearing Remover 09950 00030 Bearing Remover Attachment 09950 30012 Puller A Set 09951 03010 Upper Plate 09953 03010 Center Bolt 09954 03010 Arm 09955 03021 Claw No 2 09950 40011 Puller B Set 09951 04010 Hanger 150 90 ...

Page 92: ...ter Bolt 200 09954 04010 Arm 25 09955 04021 Claw No 2 09955 04061 Claw No 6 09957 04010 Attachment 09958 04011 Holder 09950 50013 Puller C Set No 3 clutch hub assembly 09954 05031 Claw No 3 09950 60010 Replacer Set 09951 00180 Replacer 18 Transmission case bushing 09951 00350 Replacer 35 Differential tapered roller bearing 91 ...

Page 93: ...ont bearing 09951 00560 Replacer 56 Output shaft front bearing 09950 60020 Replacer Set No 2 09951 00680 Replacer 68 Differential tapered roller bearing outer race Transaxle case side 09951 00710 Replacer 71 Differential tapered roller bearing outer race transmission case side 09950 70010 Handle Set 09951 07100 Handle 100 09951 07150 Handle 150 92 ...

Page 94: ...1U RECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgf cm Differential preload 09031 00030 Pin Punch 09040 00011 Hexagon Wrench Set 09082 00040 TOYOTA Electrical Tester 09090 04020 Engine Sling Device 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ring Pliers 93 ...

Page 95: ...PP05J 03 PP 44 PREPARATION MANUAL TRANSAXLE C60 2005 CELICA RM1131U EQUIPMENT Dial indicator with magnetic base Feeler gauge Micrometer Torque wrench Magnetic finger Wooden block or similar object 94 ...

Page 96: ... 03 PREPARATION MANUAL TRANSAXLE C60 PP 45 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Manual transaxle oil w Differential oil 2 3 liters 2 4 US qts 2 0 Imp qts API GL 4 or GL 5 SAE 75W 90 95 ...

Page 97: ...LICA RM1131U SSM Special Service Materials 08826 00090 Seal Packing 1281 THREE BOND 1281 or equivalent FIPG Transmission case x Transaxle case Transmission case x Transmission case cover 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 96 ...

Page 98: ...seal 09223 00010 Cover Seal Replacer 09350 32014 TOYOTA Automatic Transmission Tool Set 09351 32010 One way Clutch Test Tool 09351 32020 Stator Stopper 09351 32150 Oil Seal Replacer 09950 70010 Handle Set 09951 07150 Handle 150 09992 00095 Automatic Transmission Oil Pressure Gauge Set Line pressure 09992 00231 Adaptor C Line pressure 09992 00271 Gauge Assy Line pressure 97 ...

Page 99: ...PP26J 07 PP 48 PREPARATION AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09090 04020 Engine Sling Device 98 ...

Page 100: ...E U240E PP 49 2005 CELICA RM1131U EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon wrench 10 mm Torque wrench OBDII scan tool 99 ...

Page 101: ...MATIC TRANSAXLE U240E 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill Drain and refill 7 6 liters 8 0 US qts 6 7 lmp qts 4 1 liters 4 3 US qts 3 6 lmp qts ATF Type T IV or equivalent 100 ...

Page 102: ...PP26M 04 PREPARATION AUTOMATIC TRANSAXLE U240E PP 51 2005 CELICA RM1131U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 101 ...

Page 103: ... Oil Seal Puller Side gear shaft oil seal 09223 00010 Cover Seal Replacer 09350 32014 TOYOTA Automatic Transmission Tool Set 09351 32010 One way Clutch Test Tool 09351 32020 Stator Stopper 09992 00095 Automatic Transmission Oil Pressure Gauge Set Line pressure 09992 00231 Adaptor C Line pressure 09992 00271 Gauge Assy Line pressure 102 ...

Page 104: ...PP2E6 02 PREPARATION AUTOMATIC TRANSAXLE U341E PP 53 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09090 04020 Engine Sling Device 103 ...

Page 105: ...AXLE U341E 2005 CELICA RM1131U EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon wrench 10 mm Torque wrench OBDII scan tool Punch 104 ...

Page 106: ...OMATIC TRANSAXLE U341E PP 55 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill Drain and refill 6 9 liters 7 3 US qts 6 0 lmp qts 2 9 liters 3 1 US qts 2 6 lmp qts ATF Type T IV 105 ...

Page 107: ...PP2E9 02 PP 56 PREPARATION AUTOMATIC TRANSAXLE U341E 2005 CELICA RM1131U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent 106 ...

Page 108: ...ng Replacer Front drive shaft 09520 00031 Rear Axle Shaft Puller 09520 00040 Shocker Front axle Rear axle 09521 00010 Attachment Front axle 09521 00020 Rod with Grip Front axle Rear axle 09520 01010 Drive Shaft Remover Attachment Front drive shaft 09520 24010 Differential Side Gear Shaft Puller Front drive shaft 09520 32040 Shocker Set 09521 24010 Drive Shaft Boot Clamping Tool Front drive shaft 0...

Page 109: ...010 Steering Knuckle Oil Seal Replacer Front axle 09610 20012 Pitman Arm Puller Front axle Front drive shaft Front suspension 09628 10011 Ball Joint Puller Front axle Rear axle 09628 62011 Ball Joint Puller Front axle Front suspension 09710 30021 Suspension Bushing Tool Set Front drive shaft 09710 03141 Bushing Remover Base 09727 30021 Coil Spring Compressor Front suspension Rear suspension 09727 ...

Page 110: ... Front axle Front drive shaft 09950 00020 Bearing Remover Front drive shaft Rear axle 09950 60010 Replacer Set 09951 00380 Replacer 38 Front axle 09951 00550 Replacer 55 Front axle 09951 00650 Replacer 65 Front axle Front drive shaft 09950 60020 Replacer Set No 2 Front axle 09951 00730 Replacer 73 09950 70010 Handle Set Front axle Front drive shaft 09951 07150 Handle 150 109 ...

Page 111: ...ON SUSPENSION AND AXLE 2005 CELICA RM1131U RECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgf cm 09042 00010 Torx Socket T30 09090 04020 Engine Sling Device 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ring Pliers 110 ...

Page 112: ...PP08X 08 PREPARATION SUSPENSION AND AXLE PP 61 2005 CELICA RM1131U EQUIPMENT Dial indicator with magnetic base Drill Torque wrench 111 ...

Page 113: ...rive shaft joint grease Capacity Application 1ZZ FE A T Outboard side Color Yellow ocher Inboard side Color Yellow ocher 110 120 g 3 9 4 2 oz 180 190 g 6 3 6 7 oz 1ZZ FE M T and 2ZZ GE Outboard side Color Black Inboard side Color Gray 115 135 g 4 1 4 8 oz 100 120 g 3 5 4 2 oz 112 ...

Page 114: ...nkshaft Pulley Replacer 09520 00031 Rear Axle Shaft Puller 09520 00040 Shocker 09521 00020 Rod with Grip 09950 00020 Bearing Remover 09703 30010 Brake Shoe Return Spring Tool 09709 29018 LSPV Gauge Set 09718 00010 Shoe Hold Down Spring Driver 09751 36011 Brake Line Union Nut 10 x 12 mm Wrench 09843 18040 Diagnosis Check Wire No 2 113 ...

Page 115: ...PP3Y3 02 PP 64 PREPARATION BRAKE 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 114 ...

Page 116: ...PP16E 08 PREPARATION BRAKE PP 65 2005 CELICA RM1131U EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Ruler Brake drum gauge 115 ...

Page 117: ...PP16F 03 PP 66 PREPARATION BRAKE 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT 3 116 ...

Page 118: ... 00012 Rack Pinion Steering Rack Housing Stand PS gear 09612 20010 Power Steering Oil Seal Puller PS gear 09612 22011 Tilt Handle Bearing Replacer PS gear 09616 00011 Steering Worm Bearing Adjusting Socket PS gear 09617 35020 Power Steering Ring Nut Wrench PS gear 09631 12071 Steering Rack Oil Seal Test Tool PS gear 09631 20051 Steering Rack Cover C PS gear 09631 20081 Seal Ring Tool PS gear 09640...

Page 119: ... 09922 10010 Variable Open Wrench PS gear 09950 50013 Puller C Set Tilt steering column 09951 05010 Hanger 150 09952 05010 Slide Arm 09953 05020 Center Bolt 150 09954 05021 Claw No 2 09950 60010 Replacer Set 09951 00210 Replacer 21 PS gear 09951 00240 Replacer 24 PS gear 09951 00280 Replacer 28 PS vane pump PS gear 118 ...

Page 120: ...r 34 PS gear 09951 00350 Replacer 35 PS gear 09951 00400 Replacer 40 PS gear 09952 06010 Adapter PS gear 09950 70010 Handle Set 09951 07100 Handle 100 PS vane pump PS gear 09951 07150 Handle 150 PS gear 09951 07200 Handle 200 PS gear 09951 07360 Handle 360 PS gear 119 ...

Page 121: ...OLS 09025 00010 Torque Wrench 30 kgf cm PS vane pump PS gear 09042 00010 Torx Socket T30 Tilt steering column 09904 00010 Expander Set 09904 00050 No 4 Claw 09905 00012 Snap Ring No 1 Expander 09905 00013 Snap Ring Pliers Torx is a registered trademark of Textron Inc 120 ...

Page 122: ...15 PREPARATION STEERING PP 71 2005 CELICA RM1131U EQUIPMENT Caliper gauge PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS vane pump Torque wrench Vernier Calipers PS vane pump 121 ...

Page 123: ...PP0JB 08 PP 72 PREPARATION STEERING 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Power steering fluid Total 1 0 liters 1 1 US qts 0 9 lmp qts ATF DEXRON II or III 122 ...

Page 124: ...PP1W4 05 PREPARATION STEERING PP 73 2005 CELICA RM1131U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PS gear 123 ...

Page 125: ...M 2005 CELICA RM1131U SUPPLEMENTAL RESTRAINT SYSTEM SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00750 Airbag Deployment Wire Sub harness No 3 09082 00760 Airbag Deployment Wire Sub harness No 4 09843 18020 Diagnosis Check Wire 124 ...

Page 126: ...M PP 75 2005 CELICA RM1131U RECOMMENDED TOOLS 09042 00020 Torx Socket T40 Airbag sensor assembly 09082 00050 TOYOTA Electrical Tester Set 09082 00040 TOYOTA Electrical Tester 09083 00150 Test Lead Set Torx is a registered trademark of Textron Inc 125 ...

Page 127: ...NT Bolt Length 35 mm 1 38 in Pitch 1 0 mm 0 039 in Diam 6 0 mm 0 236 in Airbag disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Airbag disposal Torque wrench Vinyl bag Airbag disposal 126 ...

Page 128: ...PP0KY 07 PREPARATION BODY ELECTRICAL PP 77 2005 CELICA RM1131U BODY ELECTRICAL SST Special Service Tools 09843 18040 Diagnosis Check Wire No 2 127 ...

Page 129: ...131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09041 00030 Torx Driver T30 For removing and installing steering wheel pad 09042 00010 Torx Socket T30 For removing and installing steering wheel pad Torx is a registered trademark of Textron Inc 128 ...

Page 130: ...NT Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb 3 4 W Fuel sender gauge Bulb 21 W Turn signal flasher relay Dry cell battery Fuel sender gauge Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire 129 ...

Page 131: ...5 PP 80 PREPARATION BODY 2005 CELICA RM1131U BODY SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00740 Airbag Deployment Wire Sub harness No 2 09812 00010 Door Hinge Set Bolt Wrench 130 ...

Page 132: ...PP2DK 04 PREPARATION BODY PP 81 2005 CELICA RM1131U RECOMMENDED TOOLS 09050 20010 Air Riveter 09050 02010 Dust Cap 09050 02030 Nose Piece No 2 09060 60350 Revet Cutter 131 ...

Page 133: ...ulding Piano wire Windshield Sealer gun Brush Putty spatula Wooden block or similar object For tying both piano wire ends Plastic sheet To avoid surface damage Rope no projections difficult to break Seat belt pretensioner disposal Tire Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Seat belt pretensioner disposal Tire with disc wheel Width 185 mm 7 28 in Inner diam 360 mm 14 17 in Seat belt preti...

Page 134: ...PP0MW 04 PREPARATION BODY PP 83 2005 CELICA RM1131U LUBRICANT Item Capacity Classification MP grease 133 ...

Page 135: ...RATION BODY 2005 CELICA RM1131U SSM Special Service Materials 08833 00070 Adhesive 1324 THREE BOND 1324 or equivalent 08833 00030 Three cement black or equivalent 08850 00801 Windshield Glass Adhesive Set or equivalent 134 ...

Page 136: ...rging Hose Discharge Red 07117 88070 Refrigerant Charging Hose Suction Blue 07117 88080 Refrigerant Charging Hose Utility Green 07117 58060 Refrigerant Drain Service Valve 07117 58080 Quick Disconnect Adapter Discharge diam 16 mm 07117 58090 Quick Disconnect Adapter Suction diam 13 mm 07117 58070 T Joint 07116 38360 Gas Leak Detector Assembly 07112 76060 Magnetic Clutch Stopper 07112 66040 Magneti...

Page 137: ... 86 PREPARATION AIR CONDITIONING 2005 CELICA RM1131U 95994 10020 Snap Ring Pliers DENSO Part No 09870 00015 A C Quick Joint Puller No 1 Suction tube 09870 00025 A C Quick Joint Puller No 2 Liquid tube 136 ...

Page 138: ...PP17X 03 PREPARATION AIR CONDITIONING PP 87 2005 CELICA RM1131U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09216 00021 Belt Tension Gauge 09216 00030 Belt Tension Gauge Cable 137 ...

Page 139: ... 88 PREPARATION AIR CONDITIONING 2005 CELICA RM1131U EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor ECT switch Torque wrench Dial indicator Magnetic clutch Plastic hammer Magnetic clutch 138 ...

Page 140: ...ING PP 89 2005 CELICA RM1131U LUBRICANT Item Capacity Classification Compressor oil ND OIL 8 or equivalent When replacing condenser 40 cc 1 4 fl oz When replacing evaporator 40 cc 1 4 fl oz When replacing compressor 120 cc 4 1 fl oz 139 ...

Page 141: ...n Head Bolt Normal Recess Bolt Deep Recess Bolt Stud Bolt Weld Bolt Class 4T 5T 6T 7T 8T 9T 10T 11T No Mark w Washer No Mark No Mark w Washer SERVICE SPECIFICATIONS STANDARD BOLT SS 1 2005 CELICA RM1131U STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH 140 ...

Page 142: ...050 65 in lbf 13 26 48 76 6T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 8 19 39 71 110 170 80 195 400 730 1 100 1 750 69 in lbf 14 29 53 80 127 9 21 44 80 125 90 210 440 810 1 250 78 in lbf 15 32 59 90 7T 6 8 10 12 14 16 1 1 25 1 25 1 25 1 5 1 5 10 5 25 52 95 145 230 110 260 530 970 1 500 2 300 8 19 38 70 108 166 12 28 58 105 165 120 290 590 1 050 1 700 9 21 43 76 123 8T 8 10 12 1 25 1 25 1 25 29 61...

Page 143: ...o Mark No Mark w Washer No Mark No Mark Nut with 1 or more marks on one side surface of the nut SERVICE SPECIFICATIONS STANDARD BOLT SS 3 2005 CELICA RM1131U HOW TO DETERMINE NUT STRENGTH HINT Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas sification number when tightening parts with a bolt and nut Example Bolt 4T Nut 4N or more 142 ...

Page 144: ...SS0MG 06 SS 4 SERVICE SPECIFICATIONS MAINTENANCE 2005 CELICA RM1131U MAINTENANCE SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm 0 in 143 ...

Page 145: ... RM1131U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Front seat x Body 37 375 27 Front suspension member x Body Bolt A See page MA 7 Bolt B 113 157 1 152 1 600 83 116 Rear suspension member x Body Bolt A See page MA 7 Bolt B 80 130 816 1 326 59 96 144 ...

Page 146: ... 36 No 38 No 40 No 42 No 44 No 46 No 48 No 50 No 52 No 54 No 56 No 58 No 60 No 62 No 64 No 66 No 68 No 70 No 72 No 74 0 15 0 25 mm 0 006 0 010 in 0 25 0 35 mm 0 010 0 014 in 5 060 mm 0 1992 in 5 080 mm 0 2000 in 5 100 mm 0 2008 in 5 120 mm 0 2016 in 5 140 mm 0 2024 in 5 160 mm 0 2031 in 5 180 mm 0 2039 in 5 200 mm 0 2047 in 5 220 mm 0 2055 in 5 240 mm 0 2063 in 5 260 mm 0 2071 in 5 280 mm 0 2079 i...

Page 147: ...898 in 2 300 mm 0 0906 in 2 320 mm 0 0913 in 2 340 mm 0 0921 in 2 360 mm 0 0929 in 2 380 mm 0 0937 in 2 400 mm 0 0945 in 2 420 mm 0 0953 in 2 440 mm 0 0961 in 2 460 mm 0 0969 in 2 480 mm 0 0976 in 2 500 mm 0 0984 in 2 520 mm 0 0992 in 2 540 mm 0 1000 in 2 560 mm 0 1008 in 2 580 mm 0 1016 in 2 600 mm 0 1024 in 2 620 mm 0 1031 in 2 640 mm 0 1039 in 2 660 mm 0 1047 in 2 680 mm 0 1055 in 2 700 mm 0 10...

Page 148: ... 2172 in 15 3 15 7 mm 0 602 0 618 in Valve 1ZZ FE Valve overall length STD Intake Exhaust Minimum Intake Exhaust Valve face angle Stem diameter Intake Exhaust Stem oil clearance STD Intake Exhaust Maximum Intake Exhaust Margin thickness STD Minimum 2ZZ GE Valve overall length STD Intake Exhaust Minimum Intake Exhaust Valve face angle Stem diameter Intake Exhaust Stem oil clearance STD Intake Exhau...

Page 149: ...mum Journal oil clearance STD Maximum Journal diameter No 1 Others Circle runout Maximum Cam lobe height STD Intake Exhaust Minimum Intake Exhaust 2ZZ GE Thrust clearance STD Maximum Journal oil clearance STD No 1 Others Maximum Journal diameter No 1 Others Circle runout Maximum Cam lobe height STD Intake No 1 No 2 Exhaust No 1 No 2 Minimum Intake No 1 No 2 Exhaust No 1 No 2 0 040 0 095 mm 0 0016 ...

Page 150: ...ton ring 1ZZ FE Piston diameter at 25 6 mm 1 008 in from the piston head Piston oil clearance STD Maximum Piston ring groove clearance Piston ring end gap STD No 1 No 2 Oil Maximum No 1 No 2 Oil 2ZZ GE Piston diameter at 12 0 mm 0 048 in from the piston head Piston oil clearance STD Maximum Piston ring groove clearance Piston ring end gap STD No 1 No 2 Oil Maximum No 1 No 2 Oil 78 925 78 935 mm 3 ...

Page 151: ... Piston x Piston pin Piston pin x Connecting rod Maximum Connecting rod bolt diameter at tension portion STD Minimum 0 160 0 342 mm 0 0063 0 0135 in 0 342 mm 0 0135 in 19 788 19 840 mm 0 7791 0 7811 in 1 486 1 490 mm 0 0585 0 0587 in 1 490 1 494 mm 0 0587 0 0588 in 1 494 1 498 mm 0 0588 0 0590 in 0 028 0 060 mm 0 0011 0 0024 in 0 08 mm 0 0031 in 0 05 mm 0 0020 in 0 05 mm 0 0020 in 20 012 20 021 mm...

Page 152: ...0 0957 0 0976 in 0 015 0 032 mm 0 0006 0 0013 in 0 050 mm 0 0020 in 47 998 48 000 mm 1 8897 1 8898 in 47 996 47 998 mm 1 8896 1 8897 in 47 994 47 996 mm 1 8895 1 8896 in 47 992 47 994 mm 1 8894 1 8895 in 47 990 47 992 mm 1 8893 1 8894 in 47 988 47 990 mm 1 8892 1 8893 in 1 993 1 996 mm 0 0785 0 0786 in 1 996 1 999 mm 0 0786 0 0787 in 1 999 2 002 mm 0 0787 0 0788 in 2 002 2 005 mm 0 0788 0 0789 in ...

Page 153: ...Z FE 2ZZ GE Nut 69 100 29 704 1 020 296 51 74 21 Crankshaft position sensor x Timing chain cover 9 0 92 80 in lbf Crankshaft pulley x Crankshaft 1ZZ FE 2ZZ GE 138 120 1 409 1 200 102 87 Chain tensioner x Timing chain cover 9 0 92 80 in lbf Cylinder head cover x Cylinder head 1ZZ FE w Washer w o Washer 2ZZ GE 9 0 11 10 92 113 100 80 in lbf 8 7 No 1 ventilation pipe x Cylinder head cover 10 100 7 No...

Page 154: ...82 Bolt B Bolt C Bolt D Bolt E Nut 52 52 157 157 39 52 530 530 1 600 1 600 400 530 32 32 116 116 29 32 PS gear x Suspension member 45 460 33 Exhaust pipe 43 440 32 Clutch release cylinder x Transaxle 12 120 9 Clutch release cylinder bracket Bolt A Bolt B 12 4 9 120 50 9 43 in lbf A C Compressor x Engine 25 255 18 ECM box stay Nut Bolt 12 18 120 185 9 13 ECM box 6 9 70 61 in lbf ECM cover 6 9 70 61...

Page 155: ...5 14 18 Knock sensor 1ZZ FE 2ZZ GE 44 20 450 204 33 15 Ventilation case 2ZZ GE 8 5 87 75 in lbf Water bypass pipe x Cylinder block 1ZZ FE 2ZZ GE Bolt Nut 9 0 8 5 10 92 87 100 80 in lbf 75 in lbf 7 Dipstick guide 1ZZ FE 2ZZ GE 11 24 113 245 8 18 Fly wheel 1st 2nd 49 Turn 90 500 Turn 90 36 Turn 90 Drive plate 88 897 65 154 ...

Page 156: ...L 2005 CELICA RM1131U EMISSION CONTROL SERVICE DATA Pressure sensor for 2ZZ GE Voltage AIP E2 1 0 2 2V VSV for air switch ing valve for 2ZZ GE Resistance at 20 C 68 F 37 44 Ω Air pump relay for 2ZZ GE Terminal 1 2 Terminal 3 4 Continuity No continuity 155 ...

Page 157: ...17 2005 CELICA RM1131U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Charcoal canister x Body 18 184 13 Air switching valve x Bracket 2ZZ GE 8 82 71 in lbf Air switching valve x Body 2ZZ GE 20 5 209 15 Air pump assembly 2ZZ GE 8 82 71 in lbf 156 ...

Page 158: ...kΩ 2 5 5 9 kΩ Throttle control motor 2ZZ GE engine Resistance at 20 C 68 F 0 3 100 kΩ Camshaft timing oil control valve Resistance at 20 C 68 F 6 9 7 9 Ω VSV CCV Resistance at 20 C 68 F 24 30 Ω VSV Pressure switching valve Resistance at 20 C 68 F at 120 C 248 F 37 44 Ω 51 62 Ω VSV EVAP Resistance at 20 C 68 F 27 33 Ω VSV Intake air control valve Resistance at 20 C 68 F 37 44 Ω ECT sensor Resistanc...

Page 159: ...nd x Body 39 400 29 Throttle body x Intake manifold 1ZZ FE 21 210 15 Throttle body x Throttle gasket 2ZZ GE 22 220 16 Throttle gasket x Intake manifold 2ZZ GE 22 220 16 Camshaft timing oil control valve x Cylinder head 1ZZ FE 2ZZ GE 7 5 8 5 80 87 66 in lbf 75 in lbf Knock sensor 1 x Cylinder block 1ZZ FE 2ZZ GE 44 20 450 204 33 15 Oxygen sensor x Front exhaust pipe 44 450 33 Accelerator pedal asse...

Page 160: ... DATA Thermostat Valve opening temperature Valve lift at 90 C 194 F 80 0 84 0 C 176 183 F 10 mm 0 39 in Radiator cap Relief valve opening pressure STD Minimum 93 123 kPa 0 95 1 25 kgf cm2 13 5 17 8 psi 79 kPa 0 8 kgf cm2 11 5 psi Electric cooling fan Rotating amperage 5 2 8 2 A 159 ...

Page 161: ...g chain cover 1ZZ FE See page CO 7 Bolt A Bolt B 2ZZ GE 9 0 11 9 0 92 113 92 80 in lbf 8 80 in lbf Water pump pulley x Water pump 15 153 11 Water inlet x Cylinder block 10 100 7 Electric cooling fan x Radiator 6 0 60 53 in lbf Engine coolant reservoir x Radiator upper support 5 0 51 44 in lbf Fan motor x Fan shroud 2 55 26 23 in lbf Fan x Fan motor 6 18 63 55 in lbf 160 ...

Page 162: ... or more 39 2 kPa 0 4 kgf cm2 5 7 psi or more Oil pump Side clearance STD 1ZZ FE 2ZZ GE Maximum 1ZZ FE 2ZZ GE Tip clearance STD 1ZZ FE 2ZZ GE Maximum 1ZZ FE 2ZZ GE Body clearance STD 1ZZ FE 2ZZGE Maximum 0 025 0 071 mm 0 00098 0 00280 in 0 030 0 080 mm 0 00118 0 00314 in 0 071 mm 0 00280 in 0 160 mm 0 00630 in 0 040 0 160 mm 0 00157 0 00630 in 0 060 0 180 mm 0 00236 0 00709 in 0 160 mm 0 00630 in ...

Page 163: ...f Oil pressure switch x Cylinder block 13 130 9 Oil pressure switch x Oil control valve housing 13 130 9 Drain plug x Oil pan 37 378 27 Oil pump body cover x Oil pump body 10 5 107 8 Plug x Oil pump 1ZZ FE 2ZZ GE 37 49 375 500 27 36 Oil pump x Cylinder block 9 0 92 80 in lbf Oil nozzle x Cylinder block 9 0 92 80 in lbf 162 ...

Page 164: ...N SERVICE DATA Spark plug Recommended spark plug 1ZZ FE DENSO NGK 2ZZ GE DENSO NGK SK16R11 IFR5A11 SK20R11 IFR6A11 Camshaft position sensor Resistance at cold at hot 835 1 400 Ω 1 060 1 645 Ω Crankshaft position sensor Resistance at cold at hot 1 630 2 740 Ω 2 065 3 225 Ω 163 ...

Page 165: ... SPECIFICATION Part tightened N m kgf cm ft lbf Spark plug x Cylinder head 18 184 13 Ignition coil w Igniter x Cylinder head cover 9 0 92 79 in lbf Camshaft position sensor x Cylinder head 8 8 90 78 in lbf Crankshaft position sensor x Timing chain cover 8 8 90 78 in lbf 164 ...

Page 166: ...kW Commutator Diameter STD Minimum Undercut depth STD Minimum Circle runout Maximum Magnetic switch Contact plate for wear Maximum 12 V 1 4 kW 12 V 1 2kW 90 A or less at 11 5 V 3 000 rpm or more 15 5 mm 0 610 in 10 0 mm 0 394 in 17 6 23 5 N 1 8 2 4 kgf 4 0 5 3 lbf 13 7 19 6 N 1 4 2 0 kgf 3 1 4 6 lbf 11 8 N 1 2 kgf 2 6 lbf 8 8 N 0 9 kgf 2 0 lbf 30 0 mm 1 181 in 29 0 mm 1 412 in 0 6 mm 0 024 in 0 2 ...

Page 167: ...axle 37 380 28 End cover x Brush holder 3 8 39 34 in lbf Starter housing x Magnetic switch 9 3 95 82 in lbf End cover x Starter housing 9 3 95 82 in lbf Lead wire x Terminal C of starter 5 9 60 52 in lbf Terminal nut x Terminal C of starter Terminal 30 of starter 17 173 12 Magnetic switch end cover x Magnetic switch 2 5 26 23 in lbf 166 ...

Page 168: ...fic gravity at 20 C 68 F 12 7 12 9 V 1 25 1 29 Generator Rated output Rotor coil resistance M T A T Slip ring diameter STD Minimum Brush exposed length STD Minimum 12 V 80 A 2 7 3 1 Ω 2 1 2 5 Ω 14 2 14 4 mm 0 559 0 567 in 12 8 mm 0 504 in 10 5 mm 0 413 in 1 5 mm 0 059 in Voltage regulator Regulating voltage 13 2 14 8 V 167 ...

Page 169: ...111 1 125 81 Rectifier end frame x Brush holder Voltage regulator 2 0 20 17 in lbf Rectifier holder x Coil lead on rectifier end frame 2 9 30 25 in lbf Rear end cover x Rectifier holder 4 4 45 39 in lbf Plate terminal x Rectifier holder Nut Bolt 4 4 3 9 45 39 39 in lbf 35 in lbf Terminal insulator x Rectifier holder 4 1 42 36 in lbf Generator x RH engine mount bracket 25 20 18 Generator x Cylinder...

Page 170: ...lay at pedal top 5 0 15 0 mm 0 197 0 591 in Clutch release point from pedal full stroke end position 25 mm 0 98 in or more Slotted spring pin protrusion 1 5 2 5 mm 0 059 0 098 in Disc rivet head depth Min 0 3 mm 0 012 in Disc runout Max 0 8 mm 0 031 in Flywheel runout Max 0 1 mm 0 004 in Diaphragm spring finger wear Max depth 0 5 mm 0 020 in Diaphragm spring finger wear Max width 6 0 mm 0 236 in D...

Page 171: ...f cm ft lbf Clutch line union 15 155 11 Master cylinder installation nut 12 120 9 Bleeder plug 8 4 85 74 in lbf Release cylinder installation bolt 12 120 9 Clutch line clamp x Clutch line bracket 4 9 50 43 in lbf Flywheel set bolt 49 500 36 Clutch cover x Flywheel 19 195 14 Release fork support 37 375 27 170 ...

Page 172: ... in 0 57 mm 0 0224 in Gear radial clearance 1st 2nd 3rd 4th and 5th KOYO made STD Max 0 015 0 058 mm 0 0006 0 0023 in 0 058 mm 0 0023 in Gear radial clearance 1st 2nd 3rd 4th and 5th NSK made STD Max 0 015 0 056 mm 0 0006 0 0022 in 0 056 mm 0 0022 in No 3 gear shift fork to No 3 hub sleeve clearance Max 0 5 mm 0 020 in No 2 gear shift fork to No 2 hub sleeve clearance Max 0 35 mm 0 014 in No 1 gea...

Page 173: ...k A Mark B Mark C Mark D Mark E Mark F Mark G 2 50 mm 0 0984 in 2 56 mm 0 1008 in 2 62 mm 0 1031 in 2 68 mm 0 1055 in 2 74 mm 0 1079 in 2 80 mm 0 1102 in 1 85 mm 0 0728 in 1 90 mm 0 0748 in 1 95 mm 0 0768 in 2 00 mm 0 0787 in 2 05 mm 0 0807 in 2 10 mm 0 0827 in 2 15 mm 0 0846 in 2 20 mm 0 0866 in 2 25 mm 0 0886 in 2 31 mm 0 0909 in 2 37 mm 0 0933 in 2 43 mm 0 0957 in 2 49 mm 0 0980 in 2 55 mm 0 10...

Page 174: ...rk LL Mark MM Mark NN Mark PP Mark QQ Mark RR Mark SS Mark TT Mark UU 2 10 mm 0 0827 in 2 15 mm 0 0846 in 2 20 mm 0 0866 in 2 25 mm 0 0886 in 2 30 mm 0 0906 in 2 35 mm 0 0925 in 2 40 mm 0 0945 in 2 45 mm 0 0965 in 2 50 mm 0 0984 in 2 55 mm 0 1004 in 2 60 mm 0 1024 in 2 65 mm 0 1043 in 2 70 mm 0 1063 in 2 75 mm 0 1083 in 2 80 mm 0 1102 in 2 85 mm 0 1122 in 2 90 mm 0 1142 in 2 95 mm 0 1161 in 3 00 m...

Page 175: ...iate extension x Control valve shaft 35 360 26 Tube clamp 7 8 80 69 in lbf Pressure feed and return tubes x PS gear assembly 40 44 410 450 30 33 Engine rear mounting insulator x Engine rear mounting bracket 87 890 64 Engine rear mounting bracket x Transaxle 64 650 47 Passenger airbag assembly 20 204 15 Airbag sensor assembly x Body 20 205 15 Steering wheel lock nut 34 350 25 Shift lever assembly x...

Page 176: ...Transaxle case 29 300 22 Oil receiver pipe set bolt 17 175 13 Reverse shift arm bracket x Transaxle case 17 175 13 No 1 gear shift head set bolt 16 160 12 Output shaft front bearing lock plate set bolt 11 115 8 Transaxle case receiver x Transaxle case 11 115 8 Straight screw plug Reverse restrict pin 13 130 9 Differential case x Ring gear 77 790 57 For use without SST 175 ...

Page 177: ... mm 0 0039 0 0236 in 0 60 mm 0 0236 in Gear radial clearance 1st 2nd 3rd and 4th KOYO made STD Max 0 15 0 58 mm 0 0006 0 0023 in 0 058 mm 0 0023 in Gear radial clearance 1st 2nd 3rd and 4th NSK made STD Max 0 015 0 056 mm 0 0006 0 0022 in 0 056 mm 0 0022 in Gear radial clearance 5th STD Max 0 015 0 056 mm 0 0006 0 0022 in 0 056 mm 0 0022 in Gear radial clearance 6th STD Max 0 009 0 050 mm 0 0003 0...

Page 178: ...center radial ball bearing Mark A Mark B Mark C Mark D Mark E Mark F Input shaft rear radial ball bearing Mark A Mark B Mark C Mark D Mark E Mark F Mark G Mark H Mark J Mark K Mark L Mark M 2 30 mm 0 0906 in 2 36 mm 0 0929 in 2 42 mm 0 0953 in 2 48 mm 0 0976 in 2 54 mm 0 1000 in 2 60 mm 0 1024 in 1 75 mm 0 0689 in 1 80 mm 0 0709 in 1 85 mm 0 0728 in 1 90 mm 0 0748 in 1 95 mm 0 0768 in 2 00 mm 0 07...

Page 179: ...0 0846 in 2 20 mm 0 0866 in 2 31 mm 0 0909 in 2 37 mm 0 0933 in 2 43 mm 0 0957 in 2 49 mm 0 0980 in 2 55 mm 0 1004 in 2 61 mm 0 1028 in 2 67 mm 0 1051 in 2 73 mm 0 1075 in 2 79 mm 0 1098 in 2 85 mm 0 1122 in 2 91 mm 0 1146 in Differential tapered roller bearing adjusting shim thickness Mark AA Mark BB MarK CC Mark DD Mark EE Mark FF Mark GG Mark HH Mark JJ Mark KK Mark LL Mark MM Mark NN Mark PP M...

Page 180: ...0 33 Intermediate extension x Control valve shaft 35 360 26 Tube clamp 7 8 80 69 in lbf Pressure feed and return tubes x PS gear assembly 44 44 410 450 30 33 Engine rear mounting insulator x Engine rear mounting bracket 87 890 64 Engine rear mounting bracket x Transaxle 64 650 47 Passenger airbag assembly 20 204 15 Airbag sensor assembly x Body 20 205 15 Steering wheel lock nut 34 350 25 Shift lev...

Page 181: ...18 Straight screw plug Plug A See page MX 13 Plug B 13 39 130 400 9 29 Transmission case x Transaxle case 29 300 22 Reverse shift arm bracket x Transaxle case 17 175 13 Output shaft front bearing lock plate set bolt 11 115 8 Transaxle case receiver x Transaxle case 11 115 8 Oil receiver pipe 17 175 13 Ring gear x Differential case 77 790 57 For use without SST 180 ...

Page 182: ...lation distance 0 20 mm 0 0079 in 0 30 mm 0 0118 in More than 12 75 mm 0 5020 in Differential oil seal drive in depth LH side RH side 2 7 0 5 mm 0 106 0 020 in 0 0 5 mm 0 0 020 in Shift schedule D position Throttle valve fully opened 1 2 2 3 3 4 4 3 3 2 2 1 Throttle valve fully closed 3 4 4 3 2 position Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 3 2 2 1 60 67 km...

Page 183: ...Hood set bolt 13 130 9 No 2 cylinder head cover 7 0 71 62 in lbf ECM case set bolt 6 9 70 61 in lbf ECM set bolt 6 9 70 61 in lbf ECM bracket set bolt 18 185 13 ECM bracket set nut 12 120 9 Radiator reservoir set bolt 4 9 50 43 in lbf Ground cable x Transaxle 18 185 13 Starter x Transaxle 37 378 28 Drain plug x Differential 54 550 40 Stabilizer bar link x Shock absorber 44 450 32 Lower suspension ...

Page 184: ...lation distance 0 20 mm 0 0079 in 0 30 mm 0 0118 in More than 13 3 mm 0 524 in Differential oil seal drive in depth LH side RH side 2 7 0 5 mm 0 106 0 020 in 0 0 5 mm 0 0 020 in Shift schedule D position Throttle valve fully opened 1 2 2 3 3 O D O D 3 3 2 2 1 Throttle valve fully closed 3 O D O D 3 2 position Throttle valve fully opened 1 2 3 2 2 1 L position Throttle valve fully opened 3 2 2 1 57...

Page 185: ...30 9 No 2 cylinder head cover 7 0 71 62 in lbf ECM case set bolt 6 9 70 61 in lbf ECM set bolt 6 9 70 61 in lbf ECM bracket set bolt 18 185 13 ECM bracket set nut 12 120 9 Radiator reservoir set bolt 4 9 50 43 in lbf Ground cable x Transaxle 18 185 13 Starter x Transaxle 37 378 28 Drain plug x Differential 54 550 40 Stabilizer bar link x Shock absorber 44 450 32 Lower suspension arm x Lower ball j...

Page 186: ...15 P195 60R15 205 55R15 P205 55R15 205 50R16 Right left error 2 07 45 2 12 0 75 2 01 45 2 02 0 75 2 02 45 2 03 0 75 45 0 75 or less Steering axis inclination 195 60R15 P195 60R15 205 55R15 P205 55R15 205 50R16 Right left error 13 09 45 13 15 0 75 13 04 45 13 07 0 75 13 12 45 13 20 0 75 45 0 75 or less Toe in total Rack end length difference 0 12 0 0 2 0 2 mm 0 0 08 in 1 5 mm 0 059 in or less Wheel...

Page 187: ...abilizer bar link ball joint turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 in lbf Rear axle Axle bearing backlash Maximum 0 05 mm 0 0020 in Axle hub deviation Maximum 0 07 mm 0 0028 in Rear suspension Stabilizer bar link ball joint turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 in lbf 1 Front measuring point Measure the distance from the ground to the center of the front side lower suspensi...

Page 188: ... in lbf Lower suspension arm set bolt 137 1 397 101 PS gear set bolt 58 591 43 Engine front mount x Center member 52 530 38 Engine rear mount x Suspension member 52 530 38 Suspension member set bolt 157 1 600 116 Center member front side set bolt 39 400 29 Stabilizer bar bracket x Suspension member 19 194 14 Stabilizer bar link set nut 44 449 32 REAR AXLE Hub nut 103 1 050 76 Brake caliper set bol...

Page 189: ... SERVICE SPECIFICATIONS SUSPENSION AND AXLE SS 49 2005 CELICA RM1131U Stabilizer bar bracket set bolt 18 184 13 Stabilizer bar link set nut 44 449 32 188 ...

Page 190: ...ickness STD 10 0 mm 0 394 in Rear brake pad thickness Minimum 1 0 mm 0 039 in Rear brake disc thickness STD 9 0 mm 0 354 in Rear brake disc thickness Minimum 7 5 mm 0 295 in Rear brake disc runout Maximum 0 15 mm 0 0059 in Rear brake disc inside diameter STD 173 0 mm 6 811 in Rear brake disc inside diameter Maximum 174 0 mm 6 850 in Rear brake drum inside diameter STD 200 0 mm 7 874 in Rear brake ...

Page 191: ...rque plate x Steering knuckle 107 1 090 79 Front disc brake caliper x Flexible hose 30 310 22 Rear drum brake wheel cylinder x Backing plate 10 100 7 Rear disc brake caliper installation bolt 47 475 34 ABS actuator assembly x Body 19 195 14 ABS actuator x ABS actuator bracket assembly 5 4 55 48 in lbf Front speed sensor installation bolt 8 0 82 71 in lbf Front speed sensor harness clamp bolt 8 0 8...

Page 192: ...oil clearance STD Maximum 0 021 0 043 mm 0 0008 0 0017 in 0 07 mm 0 0028 in Vane plate height Minimum 7 6 mm 0 299 in Vane plate thickness Minimum 1 405 mm 0 0553 in Vane plate length Minimum 11 993 mm 0 4722 in Vane plate and vane pump rotor groove clearance Maximum 0 03 mm 0 0012 in Vane plate length pump rotor and cam ring mark 0 12 001 12 003 mm 0 47248 0 47256 in 1 11 999 12 001 mm 0 47240 0 ...

Page 193: ...eed tube x PS vane pump assembly 40 44 410 450 30 33 POWER STEERING GEAR Engine hanger set bolt 38 388 28 Bearing guide nut 40 410 30 Rack housing cap 74 750 54 Rack end x Steering rack 62 83 630 850 46 61 Tie rod end lock nut 74 750 54 Turn pressure tube x Rack housing 23 25 230 250 17 18 Engine rear mount bracket set bolt 64 655 47 Engine rear mount bracket x Engine rear mount insulator 87 890 6...

Page 194: ... 25 Steering wheel pad 8 8 90 78 in lbf Front passenger airbag assembly x Instrument panel reinforcement 20 205 15 Seatback assembly x Seat adjuster 43 440 32 Seat cushion assembly x Seat adjuster 21 210 15 Front seat x Body 37 375 27 Airbag sensor assembly 20 205 15 Front airbag sensor 20 205 15 Side airbag sensor assembly x body 20 205 15 Door side airbag sensor x door 8 0 82 71 in lbf 193 ...

Page 195: ... 100 100 105 120 120 125 5 140 140 146 160 160 167 TACHOMETER ON VEHICLE DC 13 5 V 25 C at 77 F Standard indication Allowable range 700 700 770 1 000 900 1 100 2 000 1 850 2 150 3 000 2 800 3 200 4 000 3 800 4 200 5 000 4 800 5 200 6 000 5 800 6 200 7 000 6 800 7 200 FUEL SENDER GAUGE Float position mm in Resistance Ω F Approx 75 9 2 99 Approx 3 0 1 2 Approx 17 2 0 68 Approx 31 6 E Approx 50 8 2 0...

Page 196: ...or panel Nut 5 4 55 48 in lbf Door lock x Door panel Screw 4 9 50 43 in lbf Outside handle x Door panel 5 4 55 48 in lbf Key cylinder x Outside handle 5 4 55 48 in lbf Door hinge x Body 25 260 19 Door hinge x Door panel 25 260 19 Door lock striker x Body 23 230 17 BACK DOOR Door lock x Door panel 5 4 55 48 in lbf Door handle x Door panel 5 4 55 48 in lbf Door hinge x Door panel 11 115 8 Door hinge...

Page 197: ...Side hinge x Body 7 8 80 69 in lbf Center hinge x Body 18 185 13 Seatback lock striker x Body 18 185 13 Seatback lock x Seatback frame 21 210 15 SEAT BELT Front seat outer belt shoulder anchor x Body 43 440 32 Front seat outer belt floor anchor x Body 43 440 32 Front seat outer belt retractor x Body Upper side 7 5 76 66 in lbf Front seat outer belt retractor x Body Lower side 43 440 32 Front seat ...

Page 198: ...0 rpm Magnetic clutch is engaged 900 50 rpm Idle up speed 1ZZ FE A T Magnetic clutch is not engaged 750 50 rpm Magnetic clutch is engaged 900 50 rpm Idle up speed 2ZZ GE M T Magnetic clutch is not engaged 750 50 rpm Magnetic clutch is engaged 850 50 rpm Idle up speed 2ZZ GE A T Magnetic clutch is not engaged 650 50 rpm Magnetic clutch is engaged 850 50 rpm Magnetic clutch clearance 0 45 0 10 mm 0 ...

Page 199: ...x Expansion valve 5 4 55 48 in lbf Pressure switch x Liquid tube 10 100 7 Pressure plate x Compressor 13 2 135 9 Liquid lines 10 100 7 Discharge lines 10 100 7 Suction lines 10 100 7 Air pump assembly set bolt 2ZZ GE 8 0 82 71 in lbf Cruise control actuator set bolt 1ZZ FE 5 5 56 49 in lbf Engine coolant reservoir set bolt 5 0 51 44 in lbf Center brace set bolt 9 8 100 87 in lbf Upper radiator sup...

Page 200: ...3 Basic Inspection P DI 3 DTC Chart P DI 42 Problem Symptoms Table P DI 39 Circuit Inspection P DI 42 Adjustment Repair DTC Check P DI 3 Items inside are titles of pages in in the bottom portion See the indicated pages for detailed explanations this manual with the page number Malfunction occurs Malfunction does not occur Parts Inspection Check for Intermittent Problems P DI 3 Identification of Pr...

Page 201: ...o D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Rainy Snowy Various Other Hot Warm Cool Cold approx C F Highway Suburbs Inner city Uphill Downhill Rough road Other Cold Warming up After warming up Any temp Other Starting Just after start...

Page 202: ... The computer In addition the applica ble Diagnostic Trouble Codes DTCs prescribed by SAE J2012 are recorded in the ECM memory See page DI 42 If the malfunction does not reoccur in 3 consecutive trips the MIL goes off automatically but the DTCs remain recorded in the ECM memory S To check the DTC connect the hand held tester or OBD II scan tool to the Data Link Connector 3 DLC3 of the vehicle The ...

Page 203: ...s detected again the MIL will illumi nate This is known as 2nd trip detection S Freeze frame data The freeze frame data records the engine condi tions fuel system calculated load engine coolant temperature fuel trim engine speed vehicle speed etc when a malfunction is detected When troubleshooting freeze frame data can help deter mining if the vehicle was running or stopped if the engine was warme...

Page 204: ...screen displays UNABLE TO CONNECT TO VEHICLE a problem exists in the vehicle side or the tester side S If the communication is normal when the tool is connected to another vehicle inspect the DLC3 on the original ve hicle S If the communication is still impossible when the tool is connected to another vehicle the problem is probably in the tool itself so consult the Service Department listed in th...

Page 205: ...ON 3 Use the OBD II scan tool or the hand held tester to check the DTCs and freeze frame data and then write them down For the hand held tester enter the following me nus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODEDS For the OBD II scan tool see its instruction manual 4 See page DI 42 to confirm the details of the DTCs NOTICE When simulating a symptom with the OBD II scan tool ex cluding hand ...

Page 206: ...ds After disconnecting the battery terminal perform the INI TIALIZE procedure 3 DTC CHECK Check Mode HINT Hand held tester only Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode cannot detect Check mode can also detect all the malfunctions that normal mode can detect a Follow these steps when preparing to use the hand held tester check mode 1 M...

Page 207: ...battery terminal perform the INI TIALIZE procedure 4 FAIL SAFE CHART If any of the following codes is recorded the ECM enters fail safe mode DTC No Fail Safe Operation Fail Safe Deactivation Conditions P0100 Ignition timing fixed at 5 BTDC Returned to normal condition P0110 Intake air temperature is fixed at 20 C 68 F Returned to normal condition P0115 Engine coolant temperature is fixed at 80 176...

Page 208: ...ny cases by carrying out the basic engine check shown in the following flowchart the location causing the problem can be found quickly and efficiently There fore using this check is essential in the engine troubleshooting 1 Is battery positive voltage 11 V or more when engine is stopped NO Charge or replace battery YES 2 Is engine cranked NO Proceed to page and continue to troubleshoot YES 3 Does ...

Page 209: ...ce OK 5 Check idle speed PREPARATION a Warm up the engine to normal operating temperature b Switch off all accessories c Switch off air conditioning d Shift transmission into N position e Connect the OBD II scan tool or the hand held tester to DLC3 on the vehicle CHECK Use CURRENT DATA to check the idle speed OK Idle speed 650 to 750 rpm NG Proceed to problem symptoms table on page DI 39 OK 208 ...

Page 210: ...ON d Use ACTIVE TEST mode to operate the fuel pump HINT Please refer to the hand held tester operator s manual for fur ther details e If you have no hand held tester connect the positive and negative leads from the battery to the fuel pump connector See page SF 1 CHECK Check for fuel pressure in the fuel inlet hose when it is pinched off HINT At this time you will hear a fuel flowing noise NG Proc...

Page 211: ...he ignition coil assembly d Disconnect the injector connector e Ground the spark plug CHECK Check if spark occurs while engine is being cranked NOTICE To prevent excess fuel being injected from the injectors during this test don t crank the engine for more than 5 10 seconds at a time NG Proceed to page IG 1 and continue to trouble shoot OK Proceed to problem symptoms table on page DI 39 210 ...

Page 212: ...Air flow rate from MAF sensor Min 0 gm s Max 655 gm s S Idling 1 4 to 2 0 gm sec S Racing without load 2 500 rpm 5 4 to 7 9 gm sec If value is approximately 0 0 gm s S Mass air flow meter power source circuit open S VG circuit open or short If value is 160 0 gm s or more S E2G circuit open ENGINE SPD Engine Speed Min 0 rpm Max 16 383 rpm Idling 650 to 750 rpm COOLANT TEMP Coolant temperature Min 4...

Page 213: ...sponse time of the O2 sensor rich to lean bank 1 sensor 1 Min 0 ms Max 16 711 ms Idling after warming up 0 to 1 000 ms IGNITION Ignition counter Min 0 Max 400 0 to 400 CYL 1 CYL 4 Misfire ratio of the cylinder Min 0 Max 50 0 This item is displayed in only idling CTP SW Closed throttle position switch ON or OFF S Throttle fully closed ON S Throttle open OFF FUEL SYS 1 Fuel system status Bank1 OL or...

Page 214: ...F Except center ON PS SIGNAL Power steering signal ON or OFF S After engine start OFF S After steer the steering ON FUEL PUMP SPD Fuel pump speed status ON H or OFF M L Idling ON A C MAG CLUTCH A C magnet clutch status ON or OFF A C magnet clutch ON ON EVAP VSV VSV status for EVAP control ON or OFF VSV operating ON VSV operating ON VVT CTRL B1 VVT control status Bank 1 ON or OFF VVT system operati...

Page 215: ... INJ VOL Test Details Control the injection volume Min 12 5 Max 24 8 Vehicle Condition Engine speed 3 000 rpm or less S All injectors are tested at once S Injection volume is gradual ly changed between 12 5 and 25 CAN CTRL VSV Test Details Activate the VSV for canister control ON or OFF TANK BYPASS VSV Test Details Activate the VSV for tank bypass ON or OFF EVAP VSV ALONE Test Details Activate the...

Page 216: ...set a DTC MIL operation MIL illumination timing after a defect is detected Immediately means that the ECM illuminates MIL the instant the ECM determines that there is a malfunction 2 driving cycle means that the ECM illuminates MIL if the same malfunction is detected again in the 2nd driving cycle 10 TOYOTA LEXUS PART AND SYSTEM NAME LIST This reference list indicates the part names used in this m...

Page 217: ... control system Throttle pedal position sensor Throttle pedal position switch Throttle position sensor switch Throttle position sensor Turbo press sensor Turbocharger pressure sensor Turbo VSV Turbocharger pressure control solenoid valve P S pressure switch Power steering pressure switch VSV for ACM Active control engine mount Speed sensor Vehicle speed sensor A Speed sensor for skid control ECU V...

Page 218: ...M1131U 11 The monitor will run whenever the following DTCs are not present Monitor disablement List HINT The table below shows the ECM monitoring status for the components listed at the top of the table when the DTCs on the left of the table are set 217 ...

Page 219: ...A21571 DI 20 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U 218 ...

Page 220: ...A21572 DIAGNOSTICS ENGINE 1ZZ FE DI 21 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 219 ...

Page 221: ...A21573 DI 22 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 220 ...

Page 222: ...A21575 DIAGNOSTICS ENGINE 1ZZ FE DI 23 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 221 ...

Page 223: ...A21576 DI 24 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 222 ...

Page 224: ...manual the description of the O2S TEST RESULT for O2S related DTCs are written in a table This table consists of 5 items 1 TEST ID a code applied to each TEST DATA 2 Description of TEST DATA 3 Conversion Factor When Conversion Factor has a value written in the table multiply the TEST DATA value appearing on the scan tool by the Conversion Factor value The result will be the required value 4 Unit 5...

Page 225: ...ays 17 as a value of the TIME 81 see the illustration on the left 2 Find the Conversion Factor value of TIME 81 in the O2S TEST RESULT chart below 0 3906 is spe cified for 81 in this chart 3 Multiply 17 in step 1 by 0 3906 Conversion Fac tor in the step 2 17 x 0 3906 6 6 4 If the answer is within the standard value the TIME 81 can be confirmed to be normal O2S TEST RESULT Chart TEST ID Description...

Page 226: ...the component is functioning normally or not The test value is the value that was used to determine the monitor result If the test value is outside the test limit mal function criterion the ECM determines the component is malfunctioning Some emissions related components have multiple test values to determine monitor result If one of these test values is outside test limit the ECM determines the co...

Page 227: ... INCMP indicates the component has not been monitored yet S PASS indicates the component is functioning normally S FAIL indicates the component is malfunction ing 6 Select the component and press ENTER If the monitor result has been PASS or FAIL the accuracy test value appears S VAL indicates the test value S LMT indicates the test limit malfunction crite rion S TLT indicates the test limit type 7...

Page 228: ...do not match the VIN can be registered or overwritten in the ECM by following this procedure 2 INPUT INSTRUCTIONS a Hand held tester The arrow buttons UP DOWN RIGHT and LEFT and numerical buttons 0 to 9 are used in order to input the VIN b Cursor Operation To move the cursor around the tester screen press the RIGHT and LEFT buttons c Alphabetical Character Input 1 Press the UP and DOWN buttons to ...

Page 229: ...ogrammed or Mismatch ECM PCM Please input the VIN PRESS EXIT Possible cause To Menu Screen 17 digitVIN displayed 3 Select VIN DTC P0630 Set VIN Previously Stored VIN Not Stored EXIT EXIT EXIT 2 VIN WRITE VIN Select VIN READ 1 VIN READ 1 VIN READ ERROR ECM does not respond the VIN 1 VIN is not written yet 2 Vehicle does not support this function DI 30 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U 3...

Page 230: ...n Continuedon next page NOTICE Do you wish to continue YES NO 1 Select DIAGNOSIS 2 Select ENHANCED OBD ll 3 Select VIN 1 VIN READ 1 VIN READ VIN Select VIN WRITE YES or NO YES 2 VIN WRITE To Menu Screen NO CONFIRMATION This function will erase the DTCs automatically after writing the VIN Do you wish to continue YES 17 digit VIN displayed VIN Previously Stored DIAGNOSTICS ENGINE 1ZZ FE DI 31 2005 C...

Page 231: ...ror SET NEW VIN Press RIGHT LEFT to shift the cursor right left Press UP DOWN to increase decrease value Or input digit with the 10 key PRESS ENTER CONFIRMATION PRESS ENTER Vehicle is stopped New Registration ENTER ENTER PRESS ENTER Communication Error ENTER COMMUNICATION ERROR PRESS EXIT Turn IG OFF then ON VIN input method The following VIN has been written correctly The DTCs have been erased co...

Page 232: ...s of complete indicates that the necessary conditions have been met to run the performance tests for the related Readiness Monitor S The Readiness Monitor will be reset to incomplete if S ECM has lost power battery or fuse S DTCs have been cleared S The conditions for running the Readiness Monitor have not been met S In the event that any Readiness Monitor shows incomplete follow the appropriate R...

Page 233: ...and preconditions 2 Drive the vehicle at 40 to 55 mph 64 to 88 km h for approximately for 3 minutes NOTICE Drive with smooth throttle operation and avoid sudden acceleration If IAT is less than 10 C 50 F when engine was started drive the vehicle at 40 to 55 mph 64 to 88 km h for additional 4 minutes 3 Drive the vehicle at 35 to 45 mph 56 to 72 km h for approximately 7 minutes NOTICE Drive with smo...

Page 234: ...IL is OFF S Fuel level is approximately 1 2 to 3 4 S Altitude is 7 800 feet 2 400m or less b Cold Soak Procedure Let the vehicle cold soak for 8 hours or until the difference between IAT and ECT becomes less than 7 C 13 F HINT Examples S Scenario 1 ECT 24 C 75 F IAT 16 C 60 F Difference between ECT and IAT is 8 C 15 F The monitor will not run because difference between ECT and IAT is greater than ...

Page 235: ...monitor will run because difference between ECT and IAT is less than 7 C 13 F The readiness test can be completed in cold ambient conditions less than 40 F 4 4 C and or at high altitudes more than 7 800 feet 2 400 m if the drive pattern is repeated a second time after cycl ing the ignition off b Drive Pattern 1 Connect the OBDII scan tool to DLC3 to check monitor status and preconditions refer to ...

Page 236: ...1 Connect the OBDII scan tool to DLC3 to check monitor status and preconditions refer to step a 2 Start the engine and allow it to idle for 2 minutes or more 3 Drive the vehicle at 25 mph 40 km h or more for at least 50 seconds 4 Stop the vehicle and allow the engine to idle for 40 seconds or more 5 Perform steps 3 and 4 ten times 6 Check the status of the readiness monitor on the scan tool displa...

Page 237: ... 1 Connect the OBDII scan tool to the DLC3 to check monitor status and preconditions refer to step a 2 Start the engine and allow it to idle for 500 seconds or more 3 Drive the vehicle at 25 mph 40 km h or more at least 2 minutes 4 Check the status of the readiness monitor on the scan tool display If readiness status did not switch to complete ensure the preconditions are met turn the ignition off...

Page 238: ...rol circuit DI 268 DI 284 Difficult to start with hot engine 1 Starter signal circuit 2 Fuel pump control circuit DI 268 DI 284 High engine idle speed Poor idling 1 A C switch circuit 2 ECM power source circuit DI 279 Low engine idle speed Poor idling 1 A C switch circuit 2 Fuel pump control circuit DI 284 Rough idling Poor idling 1 Compression 2 Fuel pump control circuit EM 3 DI 284 Hunting Poor ...

Page 239: ...e pedal depressed 7 5 to 14 V IG switch ON brake pedal depressed Below 1 5 V F PS E3 8 E1 E4 17 P BR IG switch ON Below 1 5 V VSV E3 9 E1 E4 17 R L BR IG switch ON 9 to 14 V STA E3 11 E1 E4 17 L BR Cranking 6 0 V or more HT1B E3 16 E03 E2 7 Y G W B Idling Below 3 0 V IG switch ON 9 to 14 V MREL E3 21 E1 E4 17 L B BR IG switch ON 9 to 14 V SPD E3 22 E1 E4 17 W R BR IG switch ON rotate driving wheel...

Page 240: ... 14 V Idling Pulse generation See page DI 161 IGT1 E5 10 E1 E4 17 R B BR Idling Pulse generation See page DI 187 IGT2 E5 11 E1 E4 17 R W BR Idling Pulse generation See page DI 187 IGT3 E5 12 E1 E4 17 G R BR Idling Pulse generation See page DI 187 IGT4 E5 13 E1 E4 17 R Y BR Idling Pulse generation See page DI 187 CCV E5 17 E1 E4 17 V W BR IG switch ON 9 to 14 V RSO E5 18 E01 E5 21 B W W B IG switch...

Page 241: ...h Bank 1 Sensor 1 Short in heater circuit of heated oxygen sensor Heated oxygen sensor heater ECM P0037 DI 65 Oxygen Sensor Heater Circuit Malfunction Bank 1 Sensor 2 Open or short in heater circuit of heated oxygen sensor Heated oxygen sensor heater EFI relay ECM P0038 DI 65 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 2 Short in heater circuit of heated oxygen sensor Heated oxygen sen...

Page 242: ...ure Injector ECM P0134 DI 132 Insufficient Coolant Temp for Closed Loop Fuel Control Open or short in heated oxygen sensor circuit Heated oxygen sensor EFI relay Air induction system Fuel pressure Injector Gas leakage in exhaust system ECM PCV piping P0136 DI 140 Oxygen Sensor Circuit Malfunc tion Bank 1 Sensor 2 Open or short in heated oxygen sensor circuit Heated oxygen sensor Heated oxygen sens...

Page 243: ... knock sensor 1 circuit Knock sensor 1 looseness ECM P0335 DI 178 Crankshaft Position Sensor A Circuit Malfunction Open or short in crankshaft position sensor circuit Crankshaft position sensor Signal plate ECM P0339 DI 178 Crankshaft Position Sensor Cir cuit Malfunction During engine running P0340 DI 183 Camshaft Position Sensor Cir cuit Malfunction Open or short in camshaft position sensor circu...

Page 244: ...l canister is cracked holed or damaged Fuel tank over fill check valve is cracked damaged ECM P0442 DI 225 Evaporative Emission Control System Malfunction Vacuum hose is cracked holed blocked damaged or discon nected Fuel tank cap is incorrectly installed Fuel tank cap is cracked or damaged Open or short in vapor pressure sensor circuit Vapor pressure sensor Open or short in VSV circuit for EVAP E...

Page 245: ...valve is stuck or closed A C switch circuit Air induction system PCV valve and hose ECM P0511 DI 256 Idle Control Systemcircuit P0560 DI 265 ECM BATT Malfunction Open in back up power source circuit EFI fuse ECM P0617 DI 268 Starter Relay Circuit High Short in Park Neutral position switch circuit A T Park Neutral position switch A T Clutch start switch M T ECM P0630 DI 276 VIN not Programmed or Mi...

Page 246: ...nsor 2 Oxygen Sensor Bank 1 Sensor 1 Engine Coolant Temp Sensor ECM Throttle Position Sensor IAC Valve Vapor Pressure Sensor VSV for EVAP PNP Switch Injector Camshaft Position Sensor VSV for CCV VSV for Intake Air Control VSV for Pressure Switing Valve PS Oil Pressure Sensor DIAGNOSTICS ENGINE 1ZZ FE DI 47 2005 CELICA RM1131U PARTS LOCATION 245 ...

Page 247: ...re The ECM controls the OCV based on the signals output from the sensors The VVT controller regulates the intake camshaft angle using oil pressure through the OCV As a result the relative position between the cam shaft and the crankshaft is optimized and the engine torque and fuel economy improve and exhaust emis sions decrease under overall driving conditions Also the ECM detects the actual valve...

Page 248: ... Maximum The monitor will run whenever this DTC is not present See page DI 3 Battery voltage 11 V 13 V Target duty ratio 70 Starter OFF Current cut status Not cut TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following conditions is met A or B A Output signal duty for OCV Output duty ratio is 100 always ON but target duty ratio is less than 70 B Output signal duty for O...

Page 249: ...N a Connect the hand held tester to the DLC3 b Start the engine and warm it up c Turn the ignition switch ON and push the hand held tester main switch ON d Enter the following menus DIAGNOSIS ENHANCED OBD II ACTIVE TEST VVT CTRL B1 CHECK Check the engine speed when operating the Oil control valve OCV by the hand held tester OK Tester Operation Specified Condition OCV is OFF Normal engine speed OCV...

Page 250: ... ENGINE 1ZZ FE DI 51 2005 CELICA RM1131U 3 Check for open and short in harness and connector between OCV and ECM See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page SF 78 249 ...

Page 251: ...the engine and warm it up b Disconnect the OCV connector c Apply battery positive voltage between terminals of the OCV CHECK Check the engine speed OK Rough idle or engine stalled NG Replace OCV OK 2 Check for open and short in harness and connector between OCV and ECM See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page SF 78 250 ...

Page 252: ...Valve and the VVT controller The ECM sends a target duty cycle control signal to the OCV This control signal sent to the OCV regulates the oil pressure applied to the VVT controller The VVT controller can advance or retard the intake valve camshaft Example A DTC will be set if 1 the difference between the target and actual valve timing is more than 5 degrees of the crankshaft angle CA and the cond...

Page 253: ... or more Response of valve timing 1 sec 1_CA or more WIRING DIAGRAM Refer to DTCs P0010 on page DI 48 INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warm...

Page 254: ...OK Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough idle or engine stall NG Go to step 4 OK 3 Check if DTC outputs reoccur CHECK a Clear the DTCs b Warm up the engine and drive the vehicle for 10 minutes or more c Check DTCs OK No DTC output HINT DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system These DTCs will stay even if ...

Page 255: ...ontrol valve See page SF 50 OK Go to step 7 NG 6 Replace oil control valve Go 7 Check VVT controller assembly See page EM 50 OK Go to step 9 NG 8 Replace VVT controller assembly Go 9 Check blockage of OCV oil check valve and oil pipe No 1 NG Repair or replace OK 254 ...

Page 256: ... and drive the vehicle for 10 minutes or more c Check DTCs OK No DTC output HINT DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system These DTCs will stay even if the system returns to normal after a short time Foreign objects are filtered out by the oil filter OK VVT system is OK NG Replace ECM See page SF 78 255 ...

Page 257: ...ed tooth of timing chain See page EM 16 NG Adjust valve timing OK 2 Check operation of OCV PREPARATION Start the engine CHECK a Check the engine speed when disconnect the OCV con nector b Check the engine speed when apply battery positive volt age between terminals of OCV RESULT Result Check a Check b 1 Normal engine speed Rough idle or engine stall 2 Except 1 2 Replace OCV 1 256 ...

Page 258: ...output HINT DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system These DTCs will stay even if the system returns to normal after a short time Foreign objects are filtered out by the oil filter OK VVT system is OK NG 4 Check oil control valve filter NG Replace oil control valve filter OK 5 Check oil control valve See page SF 50 OK Go to step 7 NG 6 Replace oil co...

Page 259: ...heck whether or not DTC P0011 or P0012 is stored CHECK a Clear the DTCs b Warm up the engine and drive the vehicle for 10 minutes or more c Check DTCs OK No DTC output HINT DTCs P0011 or P0012 is present when a foreign object in the engine oil enters the system These DTCs will stay even if the system returns to normal after a short time Foreign objects are filtered out by the oil filter OK VVT sys...

Page 260: ... DIAGNOSTICS ENGINE 1ZZ FE DI 61 2005 CELICA RM1131U MEMO 259 ...

Page 261: ...DI 62 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U MEMO 260 ...

Page 262: ...by setting the camshaft to the maximum retard angle when the engine speed is idling The ECM closes the OCV to retard the cam The ECM stores this value as a VVT learning value When the difference between the target valve timing and the actual valve timing is 5 degrees or less the ECM stores this in its memory If the learning value meets both of the following conditions a and b the ECM interprets th...

Page 263: ...OCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred...

Page 264: ...en Sensor Heater Control Circuit Low Bank 1 Sensor 1 DTC P0032 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 1 DTC P0037 Oxygen Sensor Heater Control Circuit Low Bank 1 Sensor 2 DTC P0038 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 2 DIC6K 02 263 ...

Page 265: ... HINT S Sensor 1 is the sensor closer to the engine body S Sensor 2 is the sensor farther away from the engine body MONITOR DESCRIPTION The sending portion of the heated oxygen sensor has a zirconia element that is used to detect oxygen con centration in the exhaust If the zirconia element is at the proper temperature and the difference of the oxy gen concentration between the inside and outside s...

Page 266: ... are not present See page DI 3 P0031 P0037 Low current Either of the following conditions is met Condition 1 or 2 1 Following conditions are met Conditions a b c d and e a Time after engine start 250 sec 500 sec b Battery voltage 10 5 V c Vehicle speed 96 6 km h 60 mph d Misfire Not detected e Pass Fail detection in this driving cycle Not detected 2 Following conditions are met Conditions a b c d ...

Page 267: ...missions related component S TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit S CID Component Identification Data is assigned to each test value S Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools TID ...

Page 268: ...ll as other data from the time when a malfunction occurred 1 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the heated oxygen sensor connector CHECK Measure resistance between the terminals HT and B of the heated oxygen sensor Resistance Bank 1 Sensor 1 5 to 10 Ω 20 C 68 F Bank 1 Sensor 2 11 to 16 Ω 20 C 68 F NG Replace heated oxygen sensor OK 2 Check EFI relay PREPARATION ...

Page 269: ...e between terminals HT1A HT1B of ECM con nectors and body ground HINT S Connect terminal HT1A to bank 1 sensor 1 S Connect terminal HT1B to bank 1 sensor 2 OK Voltage 9 to 14 V OK Replace ECM See page SF 78 NG 4 Check for open and short in harness and connector between heated oxygen sensor and ECM heated oxygen sensor and EFI main relay Marking EFI See page IN 30 NG Repair or replace harness or co...

Page 270: ...he voltage applied to these components in the MAF meter The voltage level is pro portional to the air flow through the sensor and the ECM interprets this voltage as the intake air amount The circuit is constructed so that the platinum hot wire and the temperature sensor provides a bridge circuit with the power transistor controlled so that the potential of A and B remains equal to maintain the set...

Page 271: ...ents Mass air flow meter Frequency of operation Continuous Duration 3 sec MIL operation Immediate When engine speed is at less than 4 000 rpm 2 driving cycles When engine speed is at 4 000 rpm or more Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever this DTC is not present See page DI 3 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHO...

Page 272: ... Air Flow Meter Engine Room J B EFI B R W B FL MAIN EB L B 1 E4 11 E4 G W 2 E2G B B R 3 VG 1 4 2C EFI No 1 Battery 3 2 5 1 1 2A 7 2H 12 2F MREL 21 E3 EFI Relay DIAGNOSTICS ENGINE 1ZZ FE DI 73 2005 CELICA RM1131U WIRING DIAGRAM 271 ...

Page 273: ...1 Connect OBD II scan tool or hand held tester and read value of mass air flow rate PREPARATION a Connect the OBD II scan tool or hand held tester to the DLC3 b Turn ignition switch ON and push the OBD II scan tool or hand held tester main switch ON c Start the engine d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF CHECK Read mass air flow rate o...

Page 274: ...ground OK Voltage 9 to 14 V NG Go to step 5 OK 3 Check voltage between terminal VG of ECM connector and body ground PREPARATION a Remove the ECM cover b Start the engine CHECK Measure voltage between terminal VG of ECM and body ground while engine is idling OK Voltage 1 1 to 1 5 V P or N position and A C switch OFF OK Replace ECM See page SF 78 NG 4 Check for open and short in harness and connecto...

Page 275: ...er source circuit See page DI 279 6 Check continuity between terminal EVG of ECM connector and body ground PREPARATION Remove the ECM cover CHECK Check continuity between terminal EVG of ECM connector and body ground OK Below 1 Ω NG Replace ECM See page SF 78 OK 7 Check for open in harness and connector between mass air flow meter and ECM See page IN 30 NG Repair or replace harness or connector OK...

Page 276: ...d to the flow of intake air By applying a specific current to the wire the ECM heats this wire to a given temperature The flow of incoming air cools the wire and an internal thermistor changing their resistance To maintain a constant current value the ECM varies the volt age applied to these components in the MAF meter The voltage level is proportional to the air flow through the MAF meter The ECM...

Page 277: ... See page DI 3 High voltage Engine RPM 900 rpm Idle ON Engine coolant temperature 70_C 158_F Low voltage Engine RPM 0 rpm Throttle position 0 1 V TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Mass air flow meter voltage High voltage More than 2 2 V Mass air flow meter voltage Low voltage Less than 0 4 V WIRING DIAGRAM Refer to DTC P0100 on page DI 71 276 ...

Page 278: ...e when a malfunction occurred 1 Are there any other codes besides DTC P0101 being output PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT D...

Page 279: ... in series When the resistance value of the intake air temperature sensor changes in accordance with the intake air temperature the potential at terminal THA also changes Based on this signal the ECM increases the fuel injection vol ume to improve the driveability during cold engine operation DTC No DTC Detecting Condition Trouble Area P0110 Open or short in intake air temperature sensor circuit S...

Page 280: ...is not present See page DI 3 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Intake air temperature sensor range check Fluttering Intake air temperature sensor resistance Intake air temperature Less than 98 5 Ω or more than 156 kΩ More than 140_C 284_F or less than 40_C 40_F Intake air temperature sensor range check Low voltage Intake ai...

Page 281: ... air tem perature PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR CHECK Read temperature value displayed on the hand held tester or the OBD II scan tool OK Same as...

Page 282: ...connector b Connect sensor wire harness terminals together c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read temperature value on the OBD II scan tool or the hand held tester OK Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK replace intake air temperature sensor NG 2...

Page 283: ...or connector is disconnected Before checking do a visual and contact pressure checks for the ECM connector See page IN 30 c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Repair or replace harne...

Page 284: ... and ECM PREPARATION a Disconnect the mass air flow meter connector b Turn the ignition switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Replace mass air flow meter NG 283 ...

Page 285: ...ect the E4 connector of the ECM HINT Intake air temp sensor connector is disconnected c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL IN TAKE AIR CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Repair or replace harness or connector NG Replace ECM See page SF 78 ...

Page 286: ...ine Coolant Temperature sensor is used to monitor the engine coolant temperature The ECT sensor has a thermistor that varies its resistance depending on the temperature of the engine coolant When the coolant temperature is low the resistance in the thermistor increases When the temperature is high the resistance drops The variations in resistance are reflected in the voltage output from the sensor...

Page 287: ...oolant temperature sensor resistance Coolant temperature Less than 79 Ω or more than 156 kΩ More than 140_C 284_F or less than 40_C 40_F Engine coolant temperature sensor range check Low voltage Engine coolant temperature sensor resistance Coolant temperature Less than 79 Ω More than 140_C 284_F Engine coolant temperature sensor range check High voltage Engine coolant temperature sensor resistance...

Page 288: ...temperature PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read temperature value displayed on the hand held tester or the OBD II scan tool OK Same value ...

Page 289: ...sor connector b Connect the sensor wire harness terminals together c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK replace engine coolant temperature se...

Page 290: ...sensor connector is disconnected Be fore checking do a visual and contact pressure checks for the ECM connector See page IN 30 c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Repair or replace...

Page 291: ...EPARATION a Disconnect the engine coolant temp sensor connector b Turn the ignition switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Replace engine coolant temperature sensor NG 290 ...

Page 292: ...t the E4 connector of the ECM HINT Engine coolant temp sensor connector is disconnected c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL COOLANT TEMP CHECK Read temperature value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Repair or replace harness or connector NG Replace ECM See page SF ...

Page 293: ... high the resistance drops The variations in resistance are reflected in the voltage output from the sensor The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature When the sen sor output voltage deviates from the normal operating range the ECM interprets this as a fault in the ECT sensor and sets a DTC Examples 1 Upon starting the engine the ECT is betw...

Page 294: ...thin 35 sec and stopped for 10 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case1 When temperature is fixed between 35_C 95_F and 60_C 140_F Change of engine coolant temperature value Less than 3_C 5 4_F Case2 When temperature is fixed at 60_C 140_F or more Change of engine coolant temperature value 1_C 1 8_F or less COMPONENT OPERATING RANGE Standard Value Engine coolant temper...

Page 295: ...sensor circuit S Throttle position sensor S ECM HINT After confirming DTC P0120 confirm the throttle valve opening percentage and closed throttle position switch condition using the hand held tester or the OBD ll scan tool Throttle valve opening position expressed as percentage Trouble Area Throttle valve closed Throttle valve fully open 0 0 VC circuit open VTA circuit open or shorted Approx 100 A...

Page 296: ...NG CONDITIONS The monitor will run whenever this DTC is not present See page DI 3 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Throttle position sensor range check Fluttering Throttle position sensor voltage Less than 0 1 V or more than 4 9 V Throttle position sensor range check Low voltage Throttle position sensor voltage Less than 0...

Page 297: ... ground terminal are output simultaneously terminal E2 may be open S Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well ...

Page 298: ...OS CHECK Read its value displayed on the hand held tester RESULT Accelerator Pedal Operation Throttle Valve Opening Position Proceed to Releasing and depressing 0 A From approx 0 to 75 B Approx 100 C B Check for intermittent problems See page DI 3 C Go to step 4 A 2 Check throttle position sensor a Disconnect the T1 throttle position sensor connector b Measure the resistance between the terminals ...

Page 299: ...ction Throttle Valve Specified Condition VC E4 2 E2 E4 18 2 5 to 5 9 kΩ VTA E4 23 E2 E4 18 Fully closed 0 2 to 5 7 kΩ Fully open 2 0 to 10 2 kΩ CHECK Measure the resistance between the terminals of VC and VTA of ECM connector and body ground OK Resistance 10 kΩ or higher NG Repair or replace harness or connector OK Replace ECM See page SF 78 4 Check throttle position sensor a Disconnect the T1 thr...

Page 300: ...E 1ZZ FE DI 101 2005 CELICA RM1131U 5 Check for open and short in harness and connector between ECM and throttle position sensor See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 299 ...

Page 301: ...b Measure the resistance between the terminals of the throttle position sensor OK Tester Connection Throttle Valve Specified Condition VC T1 1 E2 T1 2 2 5 to 5 9 kΩ VTA T1 3 E2 T1 2 Fully closed 0 2 to 5 7 kΩ Fully open 2 0 to 10 2 kΩ NG Replace throttle position sensor OK 2 Check for open and short in harness and connector between ECM and throttle position sensor See page IN 30 NG Repair or repla...

Page 302: ... the fully closed position the output voltage of the throttle position sensor is low When it is near the fully open position the output voltage is high The ECM checks the indicated angle of the throttle valve during stop and go conditions If the indicated angle or voltage in the closed throttle position is out of the specified range 8 times or more the ECM inter prets this as a malfunction in the ...

Page 303: ... the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides DTC P0121 being output PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main...

Page 304: ...e to vary The ECM monitors the ECT signal voltage after engine start up If after sufficient time has passed the sensor still reports that the engine is not warmed up enough for closed loop fuel control the ECM interprets this as a fault in the sensor or cooling system and sets a DTC Example The engine coolant temperature is 0_C 32_F at engine start After 5 min running time the ECT sensor still ind...

Page 305: ...op enable temperature 5 min or more after engine start When the temperature at the time of engine starting is 6 6 C 20 F or less Engine coolant temperature is less than closed loop enable temperature 20 min or more after engine start WIRING DIAGRAM Refer to DTC P0115 on page DI 87 INSPECTION PROCEDURE HINT S If DTCs P0115 P0116 and P0125 are output simultaneously the engine coolant temperature sen...

Page 306: ...TC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P0125 A P0125 and other DTCs B HINT If any other codes besides P0125 are output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 42 A 2 Check thermostat See page CO 10 NG Replace thermostat See page CO 8 OK 3 Check cooling system CHECK Check that there is defect cooling system whic...

Page 307: ...tions a b and c are met a After starting engine ECT is 10 to 30 C 22 to 86 F b Engine is warmed up c THW 75 C 167 F S Thermostat S Cooling system S Engine coolant temperature sensor S ECM MONITOR DESCRIPTION The ECM estimates the coolant temperature based on starting temperature engine loads and engine speeds The ECM then compares the estimated temperature with the actual ECT Engine Coolant Temper...

Page 308: ...ry voltage 11 0 V Throttle position learning Completed Intake air temperature at engine start 10_C 14_F 35_C 95_F Engine coolant temperature at engine start 10_C 14_F 35_C 95_F Engine coolant temperature at engine start Intake air temperature at engine start 15_C 27_F 7_C 12 6_F Accumulated time that vehicle speed reaches 128 km h 80 mph or more 20 sec TYPICAL MALFUNCTION THRESHOLDS Detection Crit...

Page 309: ...or output when estimated ECT has reached to malfunction criterion Malfunction criteria for thermostat INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warm...

Page 310: ...ECK Check that there is a defect in the cooling system which causes over cool such as abnormal radiator fan operation modified cooling system and so on NG Repair or replace cooling system OK 3 Check thermostat See page CO 10 NG Replace thermostat YES Replace ECM See page SF 78 309 ...

Page 311: ...ust gas increases And the heated oxygen sensor informs the ECM of the LEAN condition low voltage i e less than 0 45 V When the air fuel ratio is richer than the stoichiometric air fuel ratio the oxygen will be vanished from the exhaust gas And the heated oxygen sensor informs the ECM of the RICH condition high voltage i e more than 0 45 V DTC No DTC Detection Condition Trouble Area P0130 Output vo...

Page 312: ... oxygen sensor generates output voltage between 0 V and 1 0 V in response to the oxygen concentration in exhaust gas When the output voltage of the heated oxygen sensor is 0 55 V or more the ECM judges that the air fuel ratio is RICH When it is 0 4 V or less the ECM judges that the air fuel ratio is LEAN Under normal condition the output voltage from the heated oxygen sensor alternates RICH and LE...

Page 313: ...her of the following conditions 1 or 2 is met 3 times or more 1 Front oxygen sensor voltage is 0 55 V or less For 18 sec or more 2 Front oxygen sensor voltage is 0 4 V or more For 18 sec or more COMPONENT OPERATING RANGE Parameter Standard value Heated oxygen sensor voltage in normal condition 0 to 1 V O2S TEST RESULT Refer to page DI 3 for detailed information Front HO2S voltage monitor If the HO...

Page 314: ... 2F 19 2A 1 2H 7 2 3 1 B W W B EA1 Y R 1 18 E5 3 E4 12 E4 16 E3 25 E3 17 E4 5 1 2 Y R B W W B B W B HT E1 OX1A 3 B EA1 8 EA1 2 1 B 4 1 W B B R H9 Heated Oxygen Sensor Bank 1 Sensor 2 2 B HT2 E1 OX1B 3 4 1 1 W W BR Engine Room J B BR BR 1 BR 2F 27 2B 3 2F 26 2F 25 BR A A A A W B J1 J C FL MAIN BR ED EC W B J2 J C A A B W 5 IB 10 IB Battery EB EFI No 1 DIAGNOSTICS ENGINE 1ZZ FE DI 115 2005 CELICA RM...

Page 315: ...ollowed detection of a malfunction will not occur If you do not have the hand held tester turn the ignition switch OFF after performing steps from c to f then perform steps from c to f again INSPECTION PROCEDURE HINT Hand held tester only Narrowing down the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sensor or other trouble areas can be distinguished Perform ACTIVE...

Page 316: ...nsor The following of A F CONTROL procedure enables the technician to check and graph the voltage outputs of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button NOTICE If the vehicle is short of fuel the air fuel ratio becomes LEAN and heat...

Page 317: ...itch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P0130 A P0130 and other DTCs B HINT If any other codes besides P0130 is output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See pa...

Page 318: ...heated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output voltage Alternates repeatedly between less than 0 4 V and more than 0 5 V See the following table OK Go to step 9 NG 3 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the heated oxygen sens...

Page 319: ...05 CELICA RM1131U 4 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Replace EFI relay OK 5 Check for open and short in harness and connector between ECM and oxygen sensor bank 1 sensor 1 See page IN 30 NG Repair or ...

Page 320: ...OK 7 Check fuel pressure See page SF 1 CHECK Check the fuel pressure high or low pressure NG Check and repair fuel pump fuel pipe line and filter See page SF 6 OK 8 Check injector injection See page SF 22 NG Replace injector OK Replace heated oxygen sensor bank 1 sensor 1 9 Perform confirmation driving pattern HINT Clear all DTCs prior to performing the confirmation driving pattern Go 319 ...

Page 321: ...DI 122 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U 10 Is there DTC P130 being output again NO Check for intermittent problems See page DI 3 YES Replace heated oxygen sensor bank 1 sensor 1 320 ...

Page 322: ...r fuel ratio close to a stoichiometric ratio This maximizes the catalytic converter s ability to purify the exhaust gas The sensor detects oxygen level in the exhaust gas and sends this signal to the ECM The inner surface of the sensor element is exposed to outside air The outer surface of the sensor element is exposed to exhaust gas The sensor element is made of platinum coated zirconia and inclu...

Page 323: ...tatus Closed loop Time after engine start 120 sec Frequency cruise condition Number of fail judgement is incremented under the following conditions 1 and 2 or 3 and 4 is met 1 Number of cycle time data summation 10 times 2 Sum of cycle time data Sum of cycle threshold 3 Number of cycle time data summation 1 time 10 times 4 Sum of cycle time data Sum of cycle threshold x 1 2 x 10 number of summatio...

Page 324: ...on volume to 12 5 or 25 1 Connect the hand held tester to the DLC3 on the vehicle 2 Turn the ignition switch ON 3 Warm up the engine by running the engine speed at 2 500 rpm for approximately 90 seconds 4 Select the item DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform A F CONTROL with the engine in an idle condition press the right or left button RESULT Heated oxygen sensor reacts in a...

Page 325: ...check and graph the voltage outputs of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button NOTICE If the vehicle is short of fuel the air fuel ratio becomes LEAN and DTC P0133 will be recorded and the MIL then comes on NOTICE S If different...

Page 326: ...held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the hand held tester or the OBD II scan tool RESULT Display DTC output Proceed to P0133 A P0133 and other DTCs B NOTICE If any other codes besides P0133 are output perform the troubleshooting for those DTCs first B Go ...

Page 327: ... or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL O2S B1S1 d Warm up the heated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output voltage Alternates between less than 0 35 V and more ...

Page 328: ...minals HT and B of the heated oxygen sensor Resistance Bank 1 Sensor 1 5 to 10 Ω 20 C 68 F Bank 1 Sensor 2 11 to 16 Ω 20 C 68 F NG Replace heated oxygen sensor OK 4 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Re...

Page 329: ...ck for open and short in harness and connector between ECM and oxygen sensor bank 1 sensor 1 See page IN 30 NG Repair or replace harness or connector OK 6 Check air induction system See page SF 1 CHECK Check the air induction system vacuum leaks NG Repair or replace induction system OK 7 Check fuel pressure See page SF 1 CHECK Check the fuel pressure high or low pressure NG Check and repair fuel p...

Page 330: ...K Replace heated oxygen sensor bank 1 sensor 1 9 Perform confirmation driving pattern See page DI 33 HINT Clear all DTCs prior to performing the confirmation driving pattern Go 10 Is there DTC P0133 being output again YES Check for intermittent problems See page DI 3 NO Replace heated oxygen sensor bank 1 sensor 1 329 ...

Page 331: ...an 0 1 V the sensor circuit may be open or shorted MONITOR DESCRIPTION The ECM uses the heated oxygen sensor to optimize the air fuel mixture in closed loop fuel control This control helps decrease exhaust emissions by providing the catalyst with a nearly stoichiometric mixture The sensor detects the oxygen level in the exhaust gas and the ECM uses this data to control the air fuel ratio The senso...

Page 332: ...DTC P0130 on page DI 112 INSPECTION PROCEDURE HINT Hand held tester only Determining the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sen sor or other trouble areas can be distinguished Perform ACTIVE TEST using a hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST which changes the injection volume to 12 5 or 25 1 Connect the hand held tester to the DL...

Page 333: ...tput and there is about 20 seconds delay at maximum in the sensor 2 rear sensor The following of A F CONTROL procedure enables the technician to check and graph the voltage outputs of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button HINT...

Page 334: ...C chart See page DI 42 A 2 Connect the OBD II scan tool or hand held tester and read value for voltage out put of oxygen sensor bank 1 sensor 1 PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD...

Page 335: ...Measure resistance between the terminals HT and B of the heated oxygen sensor Resistance Bank 1 Sensor 1 5 to 10 Ω 20 C 68 F Bank 1 Sensor 2 11 to 16 Ω 20 C 68 F NG Replace heated oxygen sensor OK 5 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery ...

Page 336: ...M1131U 6 Check for open and short in harness and connector between ECM and oxygen sensor bank 1 sensor 1 See page IN 30 NG Repair or replace harness or connector OK 7 Check whether misfire is occurred or not by monitoring DTC and data list NG Perform troubleshooting for misfire See page DI 161 OK 8 Check air induction system See page SF 1 CHECK Check the air induction system for vacuum leaks NG Re...

Page 337: ... fuel pipe line and filter See page SF 6 OK 10 Check injector injection See page SF 22 NG Replace injector OK 11 Check gas leakage on exhaust system NG Repair or replace exhaust gas leakage point OK Replace heated oxygen sensor bank 1 sensor 1 12 Perform confirmation driving pattern See page DI 33 HINT Clear all DTCs prior to performing the confirmation pattern Go 336 ...

Page 338: ...I 139 2005 CELICA RM1131U 13 Is there DTC P0134 being output again YES Replace ECM See page SF 78 NO 14 Did vehicle run out of fuel in the past NO Check for intermittent problems YES DTC P0134 is caused by running out of fuel 337 ...

Page 339: ... acceleration and deceleration the ECM interprets this as a malfunction and illuminates the MIL and then sets a DTC 2 If the rear heated oxygen sensor voltage does not remain less than 0 05 V for a long period of time while the vehicle is running the ECM interprets this as a malfunction and illuminates the MIL and then sets a DTC 3 If the sensor s voltage drops below 0 2 V extremely LEAN status im...

Page 340: ...ow response Rear oxygen sensor voltage before the fuel cut 0 2 V Catalyst condition Warmed up Engine coolant temperature 70 C 158 F Fuel cut Continues Pass fail detection in this driving cycle Not detected TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case 1 Output voltage Crack All of the following conditions are met Conditions 1 2 and 3 1 Cumulative heated oxygen sensor monitor tim...

Page 341: ...ge from RICH y0 5 V to LEAN 0 4 V N A sec Rear HO2S slow response monitor If the elapsed time is out of the standard value the ECM interprets this as a malfunction TEST ID Description of TEST DATA Conversion Factor Unit 37 Until rear HO2S voltage drops to 0 2 V after fuel cut starting N A sec Rear HO2S element monitor If all the values 81 84 85 and 87 are out of the standard values the ECM interpr...

Page 342: ...75 C 167 F g Allow the vehicle to run at 30 mph 48 km h or more for 40 seconds or more h Stop the vehicle and run the engine at idle for 20 seconds or more i Repeat the steps g and h at least 8 times in one driving cycle j Move the shift lever into the second gear k Depress the accelerator pedal for at least 10 seconds l Allow the vehicle to run at 30 mph 48 km h or more m Immediately after step l...

Page 343: ...volume by 25 1 Connect the hand held tester to the DLC3 2 Turn the ignition switch to ON and turn the hand held tester ON 3 Warm up the engine by running the engine at 2 500 rpm for approximately 90 seconds 4 On the hand held tester select the following menu items DIAGNOSIS ENHANCED OBD II ACTIVE TEST A F CONTROL 5 Perform the A F CONTROL operation with the engine idling press the right or left bu...

Page 344: ...n Almost no reaction Result DIAGNOSTICS ENGINE 1ZZ FE DI 145 2005 CELICA RM1131U The following A F CONTROL procedure enables the technician to check the graph of the voltage outputs of both front and rear heated oxygen sensors To display the graph enter ACTIVE TEST A F CONTROL USER DATA select O2S B1S1 and O2S B1S2 by pressing the YES button and then the ENTER Then press the F4 button NOTICE If th...

Page 345: ...e run the engine at 2 500 rpm for 3 minutes CHECK Read the voltage output of the heated oxygen sensor when the engine speed is suddenly increased HINT Quickly accelerate the engine to 4 000 rpm for 3 minutes by using the accelerator pedal OK Heated oxygen sensor output voltage Fluctuates repeatedly between less than 0 4 V and more than 0 5 V OK Go to step 6 NG 3 Inspect heated oxygen sensor heater...

Page 346: ...arness and connectors between ECM and heated oxygen sensor See page IN 30 NG Repair or replace harness or connector OK 6 Perform confirmation of driving pattern GO 7 Is DTC P0136 or P0138 output again NO Check for intermittent problems See page DI 3 YES Replace heated oxygen sensor 345 ...

Page 347: ... value it is detected as a malfunction and the MIL is illuminated DTC No DTC Detection Condition Trouble Area P0171 When air fuel ratio feedback is stable after warming up engine fuel trim is considerably in error on LEAN side 2 trip detection logic S Air induction system S Injector blockage S Mass air flow meter S Engine coolant temperature sensor S Fuel pressure S Gas leakage in exhaust system S...

Page 348: ...ination of smoothed short term fuel trim fuel feedback compensation value and smoothed long term fuel trim learning value of the air fuel ratio When the smoothed fuel trim learning val ue exceeds the DTC threshold the ECM interprets this as a fault in the fuel system and sets a DTC Example If the smoothed fuel trim learning value is more than 1 35 or less than 0 65 the ECM interprets this as a mal...

Page 349: ...r less varies with ECT WIRING DIAGRAM Refer to DTC P0130 on page DI 112 INSPECTION PROCEDURE HINT Hand held tester only Determining the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sen sor or other trouble areas can be distinguished Perform ACTIVE TEST using a hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST which changes the injection volume to 12 5...

Page 350: ...utput and there is about 20 seconds delay at maximum in the sensor 2 rear sensor The following A F CONTROL procedure enables the technician to check and graph the voltage outputs of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button HINT S...

Page 351: ...induction system See page SF 1 CHECK Check the air induction system for vacuum leaks NG Repair or replace air induction system OK 2 Check connection of PCV piping NG Repair or replace PCV piping OK 3 Check injector injection See page SF 22 NG Replace injector OK 350 ...

Page 352: ...e 1 Apply battery voltage terminals B and E2G 2 Connect the positive tester probe to terminal VG and negative tester probe to terminal E2G 3 Blow air into the mass air flow sensor and check that the voltage fluctuates b Resistance inspection Measure the resistance between the terminals of the in take air temperature sensor OK Tester Connection Temperature Specified Condition THA M1 4 E2 M1 5 20 _C...

Page 353: ... 59 kΩ 80_C 176_F 0 310 to 0 326 kΩ NOTICE If you checking the engine coolant temperature sensor in water be careful not to allow water to go into the terminals After checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity ...

Page 354: ...U 7 Check fuel pressure See page SF 1 CHECK Check the fuel pressure high or low pressure NG Check and repair fuel pump fuel pipe line and filter See page SF 6 OK 8 Check gas leakage on exhaust system NG Repair or replace exhaust gas leakage point OK 353 ...

Page 355: ...eated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output voltage Alternates repeatedly between less than 0 4 V and more than 0 5 V See the following table OK Go to step 17 NG 10 Check resistance of heated oxygen sensor heater PREPARATION Disconnect the heated oxygen sen...

Page 356: ... 157 2005 CELICA RM1131U 11 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Replace EFI relay OK 12 Check for open and short in harness and connector between ECM and oxygen sensor See page IN 30 NG Repair or replace...

Page 357: ...1 c Switch the hand held tester from the normal mode to the check mode See page DI 3 L1 d Start the engine and let it idle until engine coolant temperature is 75 C 167 F or more L2 e Drive the vehicle at 19 mph 30 km h or more for 3 minutes or more L3 f Let the engine idle for approx 2 minutes L4 g Perform steps e and g at least 3 times HINT If a malfunction exists the MIL will be illuminated duri...

Page 358: ...16 Confirm if vehicle has run out of fuel in past NO Check for intermittent problems See page DI 3 YES DTC P0171 or P0172 is caused by running out of fuel 17 Perform confirmation driving pattern HINT Clear all DTCs prior to performing the confirmation driving pattern Refer to step 14 Go 18 Is there DTC P0171 or P0172 being output again No Go to step 22 Yes 19 Replace heated oxygen sensor Go 357 ...

Page 359: ...irmation driving pattern Refer to step 14 Go 21 Is there DTC P0171 or P0172 being output again B Replace ECM See page SF 78 and perform confirmation driving pattern Refer to step 14 A 22 Confirm if vehicle has run out of fuel in past NO Check for intermittent problems See page DI 3 YES DTC P0171 or P0172 is caused by running out of fuel 358 ...

Page 360: ...ition sensor and the crankshaft position sensor The camshaft position sensor is used to identify misfiring cylinders and the crankshaft position sensor is used to measure variations in the crankshaft rotation speed A misfire is counted when crankshaft rotation speed variations exceed threshold values If the misfiring rate exceeds the threshold value and could cause emissions deterioration the ECM ...

Page 361: ...OR DESCRIPTION The ECM illuminates the MIL 2 trip detection logic if The ECM will illuminate the MIL when the percentage of misfire exceeds the specified limit per 1 000 engine revolutions One occurrence of excessive misfire during engine start will illuminate the MIL Four occur rences are required to illuminate the MIL 1 000 revolutions after engine start The ECM blinks the MIL MIL blinks immedia...

Page 362: ...elated misfire Every 200 revolutions 1 or 3 times catalyst deteriorating misfire MIL operation 2 driving cycles MIL ON Immediate MIL blinking Catalyst deteriorating misfire Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 3 Battery voltage 8 V Throttle position learning Completed VVT syste...

Page 363: ... B R B Engine Room J B FL MAIN Instrument Panel J B B O Battery 2C 10 2C 8 2C 9 2C 7 2G 4 EM Ignition Switch B R IG2 AM2 IG2 Relay 3 5 2 1 2F 14 2A 1 2F 16 B R B R B O Instrument Panel J B IC 9 IK 11 5 6 AM2 IG2 IK 4 IC 6 I10 I6 I7 I8 I9 DI 164 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U WIRING DIAGRAM 362 ...

Page 364: ... was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred S If the misfire does not occur when the vehicle is brought to the workshop the misfire can be confirmed by reproducing the condition of the freeze frame data Also after finishing the repair confirm that there is no misfire See confirmati...

Page 365: ...splay DTC output Proceed to P0300 P0301 P0302 P0303 and or P0304 A P0300 P0301 P0302 P0303 and or P0304 and other DTCs B HINT If any other codes besides P0300 P0301 P0302 P0303 or P0304 are output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 42 A 2 Check harness connector and vacuum hose in engine room CHECK a Check the connection conditions of the wire h...

Page 366: ...ter or the OBD II scan tool main switch ON c Start the engine d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL CYL 1 to CYL 4 CHECK Read the number of misfire on the hand held tester or the OBD II scan tool HINT When a misfire is not reproduced be sure to branch below based on the stored DTC RESULT High Misfire Rate Cylinder Proceed to 1 or 2 cylinder...

Page 367: ...t wet with gasoline or oil c Electrode gap 1 0 to 1 3 mm 0 039 to 0 051 in NOTICE If adjusting the gap of a new spark plug bend only the base ground electrode Do not touch the tip Never attempt to adjust the gap on a used plug PREPARATION a Install the spark plug to the ignition coil assembly b Disconnect the injector connector c Ground spark plug CHECK Check if spark occurs while engine is being ...

Page 368: ...connect the injector connector c Ground the spark plug CHECK Check if spark occurs while the engine is being cranked CAUTION Always disconnect each injector connector NOTICE Do not crank the engine for more than 2 seconds OK Spark jumps across electrode gap OK Replace spark plug NG 7 Check for open and short in harness and connector between ignition coil and ECM See page IN 30 OK Replace ignition ...

Page 369: ... of the ECM con nector and body ground OK Voltage 9 to 14 V OK Go to step 11 NG 9 Check resistance of injector of misfiring cylinder See page SF 22 NG Replace injector OK 10 Check for open and short in harness and connector between ignition switch and injector injector and ECM of misfiring cylinder See page IN 30 NG Repair or replace harness or connector OK 11 Check injector injection and volume o...

Page 370: ...iring cylinder See page EM 4 NG Adjust valve clearance OK 14 Check result of step 4 switch step by number of misfire cylinder High misfire rate cylinder Proceed to 1 or 2 cylinders A more than 3 cylinders B B Check for intermittent problems See page DI 3 A 15 Check valve timing Check for loose or a jumped tooth of the timing chain See page EM 16 NG Adjust valve timing OK 369 ...

Page 371: ...ster enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR 2 Read its value displayed on the hand held tester or the OBD II scan tool OK Equivalent to ambient temperature b Check the air flow rate 1 When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF 2 Read its value displayed on the hand held tester or the OBD II scan tool OK Co...

Page 372: ...nt temperature sensor in wa ter be careful not to allow water to go into the terminals Af ter checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor Compare these values to the resistance temperature graph Ch...

Page 373: ...ondition Trouble Area P0325 No knock sensor 1 signal to ECM with engine speed 2 000 rpm or more S Open or short in knock sensor 1 circuit S Knock sensor 1 looseness S ECM HINT If the ECM detects above diagnosis conditions it operates the fail safe function in which the corrective retard angle value is set to the maximum value Reference INSPECTION USING OSCILLOSCOPE S With the engine racing 4 000 r...

Page 374: ...r and sets a DTC MONITOR STRATEGY Related DTCs P0325 Knock sensor Bank 1 range check or rationality Required sensors components Main sensors components Knock sensor Related sensors components Crankshaft position sensor Camshaft position sensor Engine coolant temperature sensor Mass air flow meter Frequency of operation Continuous Duration 10 sec MIL operation Immediate Sequence of operation None T...

Page 375: ...e frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 374 ...

Page 376: ...ce between terminal KNK1 of the ECM con nector and body ground OK Resistance 10 kΩ or higher OK Go to step 3 NG 2 Check knock sensor 1 See page SF 72 NG Replace knock sensor 1 OK 3 Check for open and short in harness and connector between ECM and knock sensor 1 See page IN 30 NG Repair or replace harness or connector OK 4 Does malfunction disappear when a good knock sensor 1 is installed YES Repla...

Page 377: ...e revolution this sensor communicates the rotation of the NE signal plate as a pulse signal to the ECM Based on the signal the ECM controls fuel injection time and ignition timing DTC No DTC Detecting Condition Trouble Area P0335 No crankshaft position sensor signal to ECM during cranking 2 trip detection logic S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Si...

Page 378: ...nents Engine speed sensor Frequency of operation Continuous Duration Case 1 4 7 sec Case 2 0 016 sec MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 3 Case 1 Starter ON Minimum battery voltage while starter is ON 11 V Case 2 Engine speed 600 rpm Starter OFF Tim...

Page 379: ...ean or rich as well as other data from the time when a malfunction occurred S READ VALUE OF HAND HELD TESTER OR OBD II SCAN TOOL a Connect the hand held tester or the OBD II scan tool to the DLC3 b Start the engine and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL ENGINE SPD S The eng...

Page 380: ...Specified Condition 1 2 1 630 to 2 740 Ω at cold 2 065 to 3 225 Ω at hot NOTICE Cold and Hot shown above mean the temperature of the coils themselves Cold is from 10_C 14_F to 50 _C 122 _F and Hot is from 50 _C 122 _F to 100 _C 212 _F NG Replace crankshaft position sensor OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor See page IN 30 NG Repair or r...

Page 381: ...005 CELICA RM1131U 4 Check teeth of crankshaft timing pulley PREPARATION Remove the crankshaft angle sensor plate See page EM 16 CHECK Check the teeth of sensor plate NG Replace crankshaft timing pulley OK Replace ECM See page SF 78 380 ...

Page 382: ...very engine revolution The ECM detects the crankshaft angle and the en gine revolution based on the NE signals and the cylinder and the angle of the VVT based on the combina tion of the G2 and NE signals DTC No DTC Detection Condition Trouble Area P0340 S No camshaft position sensor signal to ECM during cranking 2 trip detection logic S No camshaft position sensor signal to ECM with engine speed 6...

Page 383: ... P0340 case 1 no signal 2 driving cycles P0340 case 2 mis aligned P0341 Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 3 P0340 Case 1 No signal Starter ON Minimum battery voltage while starter is ON 11 V P0340 Case 2 Mis aligned Engine speed 600 rpm Starter OFF P0341 Engine rev...

Page 384: ...he engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check resistance of camshaft position sensor Signal generator CHECK Measure the resistance between the terminals of camshaft position sensor connector Standard Tester Connection Specified Condition 1 2 825 to 1 400 Ω at cold 1 060 to 1 645 Ω at hot NOTICE Cold and...

Page 385: ...E 1ZZ FE 2005 CELICA RM1131U 3 Inspect sensor installation CHECK Check the camshaft position sensor installation NG Tighten the sensor OK 4 Inspect camshaft See page EM 50 NG Replace camshaft OK Replace ECM See page SF 78 384 ...

Page 386: ...is a 1 cylinder ignition system which ignites one cylinder with one ignition coil In the 1 cylinder ignition system one spark plug is connected to the end of the secondary winding High voltage is generated in the secondary winding and is applied directly to the spark plug The spark of the spark plug passes from the center electrode to the ground electrode The ECM determines the ignition timing and...

Page 387: ... B16829 IGT signal waveform 2 V Division IGT GND IGF GND 20 m sec Division DI 188 DIAGNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U DTC No DTC Detection Condition Trouble Area P0351 P0352 P0353 P0354 No IGF signal to ECM while engine is running S Ignition system S Open or short in IGF or IGT circuit from ignition coil with ignit er to ECM ignition coil circuit 1 through 4 S No 1 to No 4 ignition coil ...

Page 388: ...the IGT it interprets this as a fault in the igniter and sets a DTC MONITOR STRATEGY Related DTCs P0351 No 1 ignition coil with igniter circuit malfunction P0352 No 2 ignition coil with igniter circuit malfunction P0353 No 3 ignition coil with igniter circuit malfunction P0354 No 4 ignition coil with igniter circuit malfunction Required sensors components Igniter Frequency of operation Continuous ...

Page 389: ...ditions are met Conditions a and b a Engine speed 500 rpm b Battery voltage 6 V 2 Following conditions are met Conditions a and b a Engine speed 500 rpm b Battery voltage 10 V TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Ignition signal fail count More than 2 times Ignition signal fail count is as follows When IGF should have returned despite sending IGT COMPONENT OPERATING RANGE St...

Page 390: ...R W 3 Ignition Coil and Igniter No 2 4 2 1 B Y B W B 3 Ignition Coil and Igniter No 3 4 2 1 G R B Y B W B 3 Ignition Coil and Igniter No 4 4 2 1 R Y B Y B W B B 1 2 C C C C C C W B W B EC 3 2 5 1 14 2F Instrument Panel J B I10 Ignition Switch IG2 IG2 AM2 16 2F 1 2A 2H 7 2G 4 W B W B EB IC 6 IK 4 B O 6 5 AM2 B R B R B R IK 11 IC 9 12 E5 13 E5 EM I2 I3 I4 I5 N1 Noise Filter DIAGNOSTICS ENGINE 1ZZ FE...

Page 391: ...alfunction occurred 1 Check spark plug and spark of misfiring cylinder See page IG 1 NG Go to step 4 OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and ignition coil with igniter See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminals IGF of ECM connector and body ground PREPARATION a Remove the ECM cover b Disconnect ...

Page 392: ...nector and body ground PREPARATION Remove the ECM cover CHECK Measure voltage between terminals IGT1 to 4 of the ECM con nector and body ground when engine is cranked OK Voltage More than 0 1 V and less than 4 5 V NG Replace ECM See page SF 78 OK 6 Check voltage between terminals IGT1 to 4 of ECM connector and body ground PREPARATION Disconnect the ignition coil with igniter connector CHECK Measur...

Page 393: ...Measure voltage between terminal 1 of ignition coil with igniter connector and body ground when ignition switch is turned to ON and START position OK Voltage 9 to 14 V OK Repair ignition coil with igniter OK 8 Check for open and short in harness and connector between ignition switch and ignition coil with igniter See page SF 78 NG Repair or replace harness or connector OK Replace ignition coil wit...

Page 394: ... Rear Oxy gen Sensor sensor 2 The catalyst efficiency monitor compares the sensor 1 and sensor 2 signals in order to calculate TWC ability to store the oxygen During normal operation the TWC stores and releases oxygen as needed This results in low oxygen varia tions in the post TWC exhaust stream as shown below DTC Detecting Condition Trouble Area P0420 After the engine and the catalyst are warmed...

Page 395: ...MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Item Minimum Maximum These DTC is not present See page DI 3 Accumulated time that all of the following conditions are met 30 sec Battery voltage 11 V Intake air temperature 10_C 14_F Idle status OFF MAF 5 1 g sec 30 g sec Engine RPM 4500 rpm Engine coolant temperature 75 C 167 F Fuel system status Closed loop Cat...

Page 396: ...t monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 0 01 Multiplied by 0 0078 no dimension Catalyst deterioration level Malfunction criteria for catalyst deterioration CONFIRMATION DRIVING PATTERN a Clear the DTC b Warm up the engine until the engine coolant temperature reaches 75 C 167 F c Drive the vehicle at 40 to 55 mph 64 to 88 km h for at least 3 minutes d Dr...

Page 397: ...Check DTC other than P0420 If DTCs other than P0420 are present troubleshoot those DTCs first RESULT DTC Proceed to P0420 A P0420 and others B B Go to relevant DTC chart See page DI 42 A 2 Check gas leakage on exhaust system NG Repair or replace exhaust gas leakage point OK 396 ...

Page 398: ...remely rich or lean fuel trim Exhaust gas leak etc Almost no reaction Almost no reaction Almost no reaction Almost no reaction Catalysts Go to Front heated oxygen sensor sensor 1 Rear heated oxygen sensor sensor 2 DIAGNOSTICS ENGINE 1ZZ FE DI 199 2005 CELICA RM1131U 3 Perform A F CONTROL active test a Connect the hand held tester to the DLC3 b Run the engine at 2500 rpm for 90 seconds c Allow the ...

Page 399: ...005 CELICA RM1131U B Replace heated oxygen sensor bank 1 sensor 1 See page EM 117 C Replace heated oxygen sensor bank 1 sensor 2 See page EM 117 D Check fuel trim See page DI 148 A Replace front exhaust pipe catalyst See page EM 117 398 ...

Page 400: ... DIAGNOSTICS ENGINE 1ZZ FE DI 201 2005 CELICA RM1131U MEMO 399 ...

Page 401: ...CRIPTION The vapor pressure sensor canister closed valve CCV pressure switching valve are used to detect abnor malities in the evaporative emission control system The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components within ...

Page 402: ...damaged S Charcoal canister is cracked holed or damaged S Fuel tank over fill check valve is cracked or damaged S ECM Negative pressure incoming in the charcoal canister and fuel tank does not stop during purge cut off 2 trip detection logic P0446 No rising of the fuel tank pressure when commanding the CCV to open after the EVAP leak test No changing of the fuel tank pressure when commanding the p...

Page 403: ...e does not rise no vacuum generated the ECM determines that the CCV is stuck closed The ECM will turn on the MIL and a DTC will be set b Pressure switching valve stuck closed The ECM checks for a pressure switching valve stuck closed malfunction by commanding the pres sure switching valve to close after an EVAP leak test If the fuel tank pressure does not change the ECM determines that the pressur...

Page 404: ...mmHg Purge VSV stuck open Either of the following conditions is met Condition 1 or 2 1 Minimum fuel tank pressure before leak check Fuel tank pressure 14 sec after leak check 0 467 kPa 3 5 mmHg or more 2 Fuel tank pressure 14 sec after leak check Less than 3 733 kPa 28 mmHg P0446 Detection Criteria Threshold Case 1 CCV stuck closed Fuel tank pressure when the CCV is opened No change Case 2 CCV stu...

Page 405: ...nit Conversion is used to calculate the test value indicated on generic OBD ll scan tools TID 02 EVAP system Vacuum monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 01 Multiplied by 0 0916 mmHg Test value of EVAP VSV Determined by fuel tank pressure change during vacuum introduction Malfunction criteria for EVAP VSV 1 02 Multiplied by 0 0458 subtract 2 93 mmHg T...

Page 406: ...446 CCV or pressure switching valve P0451 P0452 or P0453 See page DI 247 is output with DTC P0442 or P0456 See page DI 225 first troubleshoot DTC P0441 P0446 P0451 P0452 or P0453 If no malfunction is detected troubleshoot DTC P0442 or P0456 next S Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected...

Page 407: ...a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 406 ...

Page 408: ... right or left but ton CHECK When the EVAP VSV is operated by the hand held tester check whether the disconnected hose applies suction to your finger OK VSV is ON Disconnected hose applies suction to your finger VSV is OFF Disconnected hose applies no suction to your finger OK Go to step 9 NG 6 Check vacuum hose between intake manifold and EVAP VSV and EVAP VSV and charcoal canister CHECK a Check ...

Page 409: ...ation of EVAP VSV See page SF 61 NG Replace EVAP VSV OK 8 Check for open and short in harness and connector between EFI main relay Marking EFI and EVAP VSV and EVAP VSV and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 408 ...

Page 410: ...the ACTIVE TEST and operate CAN CTRL VSV Press the right or left button CHECK Check the VSV operation when it is operated by the hand held tester OK VSV is ON Air does not flow from port E to port F VSV is OFF Air from port E flows out through port F OK Go to step 13 NG 10 Check vacuum hose between CCV and charcoal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacu...

Page 411: ...push the hand held tes ter main switch ON b Select the ENHANCED OBD II ACTIVE TEST mode on the hand held tester c Select the item TANK BYPASS VSV ALL in the AC TIVE TEST and operate TANK BYPASS VSV Press the right or left button d Check the VSV operation when it is operated by the hand held tester CHECK Check the VSV operation when it is operated by the hand held tester OK VSV is ON Air from port ...

Page 412: ...ther there are signs of any accident near fuel tank CHECK Check for cracks deformation and loose connection of the fol lowing parts S Fuel tank S Fuel tank filler pipe S Hoses and tubes around fuel tank NG Repair or replace evaporative emission leak part OK 17 Check vacuum hoses between vapor pressure sensor and fuel tank charcoal canister and pressure switching valve CHECK a Check that the vacuum...

Page 413: ...ap pipe and fuel tube under the floor fuel tube under the floor and charcoal canister b Check the hose and tube for cracks hole and damage NG Repair or replace hose and tube OK 19 Check voltage between terminals VC and E2 of ECM connector CHECK a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals VC and E2 of the ECM connector OK Voltage 4 5 to 5 5 V NG ...

Page 414: ...or pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor NOTICE Vacuum applied to vapor pressure sensor must be less than 66 7 kPa 500 mmHg 19 7 in Hg OK Condition 1 Voltage 2 9 to 3 7 V Condition 2 Voltage 0 5 V or less OK Go to step 22 NG 21 Check for open and short in harness and connector between vapor pressure sens...

Page 415: ...GNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U 23 Check fuel tank NG Replace fuel tank OK 24 Check charcoal canister for cracks hole and damage NG Repair or replace charcoal canister OK Replace ECM See page SF 78 414 ...

Page 416: ... Replace with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 415 ...

Page 417: ...n vapor pressure sensor and fuel tank charcoal canister and pressure switching valve and pressure switching valve and char coal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks hole and damage NG Repair or connect VSV or sensor connector OK 7 Check hose and tube between fuel tank and charco...

Page 418: ...s and disconnection c Check the vacuum hose for cracks hole damage and blockage NG Repair or replace vacuum hose OK 9 Check connector for EVAP VSV connector for CCV connector for pressure switching valve and vapor pressure sensor connector for looseness and discon nection NG Repair or connect or sensor connector OK 10 Check charcoal canister for cracks hole and damage NG Check and replace charcoal...

Page 419: ...ween terminals PTNK and E2 of ECM connectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connectors at following condition 1 and 2 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor NOTI...

Page 420: ...ge SF 78 14 Check EVAP VSV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check VSV function 1 Connect between terminal EVP1 of the ECM con nector and body ground VSV ON 2 Disconnect between terminal EVP1 of the ECM connector and body ground VSV OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK Go to step 17 ...

Page 421: ... or connector OK Replace ECM See page SF 78 17 Check CCV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect between terminal CCV of the ECM con nector and body ground VSV ON 2 Disconnect between terminal CCV of the ECM con nector and body ground VSV OFF OK 1 VSV is ON Air does not flow from port E to port F 2 VSV is OFF Air from port E flows out...

Page 422: ... 78 20 Check pressure switching valve PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect between terminal TBP of the ECM connec tor and body ground VSV ON 2 Disconnect between terminal TBP of the ECM con nector and body ground VSV OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK ...

Page 423: ...EFI and pressure switching valve and pressure switching valve and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 23 Check fuel tank inlet valve NG Replace fuel tank inlet valve OK 24 Check fuel tank NG Replace fuel tank OK It is likely that vehicle user did not properly close fuel tank cap 422 ...

Page 424: ...rol System Leak Detected Very Small Leak CIRCUIT DESCRIPTION The vapor pressure sensor andthe canister closed valve CCV are used to detect abnormalities in the evap orative emission control system The ECM decides whether there is an abnormality in the evaporative emis sion control system based on the vapor pressure sensor signal DTC P0442 or P0456 is recorded by the ECM when evaporative emissions ...

Page 425: ...or short in circuit for EVAP S EVAP VSV S Open or short in circuit for CCV S CCV S Fuel tank is cracked holed or damaged S Charcoal canister is cracked holed or damaged S Fuel tank over fill check valve is cracked or damaged S ECM P0456 The pressure in the EVAP system slightly increases while the ECM performs a leak check very small leak 2 trip detection logic HINT Typical DTC output of each troub...

Page 426: ... value c Opens the EVAP VSV This introduces a negative pressure from the intake manifold to the fuel tank d Closes the EVAP VSV to seal the fuel tank for storing the negative pressure e Monitors the increase in fuel tank pressure for 1 Rapid increase in the internal pressure i e a large leak 0 040 or more 2 A pressure rise just above normal i e a small leak 0 020 If the ECM detects either of the a...

Page 427: ...owing conditions is met Condition 1 or 2 1 Purge duty cycle 15 When vehicle speed is 8 g sec or more 2 Purge concentration for 30 sec 5 When vehicle speed is less than 10 km h 6 2 mph Fuel slosh No sloshing i e fairy smooth road Fuel tank pressure change before vacuum introduction Minimum change Fuel level 90 0 04 inch leak detection Not detected CCV malfunction pressure switching valve malfunctio...

Page 428: ...ues after performing the monitor drive pattern see page DI 3 S TID Test Identification Data is assigned to each emissions related component S TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit S CID Component Identification Data is assigned to ...

Page 429: ...place with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 428 ...

Page 430: ... right or left but ton CHECK When the EVAP VSV is operated by the hand held tester check whether the disconnected hose applies suction to your finger OK VSV is ON Disconnected hose applies suction to your finger VSV is OFF Disconnected hose applies no suction to your finger OK Go to step 9 NG 6 Check vacuum hose between intake manifold and EVAP VSV and EVAP VSV and charcoal canister CHECK a Check ...

Page 431: ...ation of EVAP VSV See page SF 61 NG Replace EVAP VSV OK 8 Check for open and short in harness and connector between EFI main relay Marking EFI and EVAP VSV and EVAP VSV and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 430 ...

Page 432: ... the ACTIVE TEST and operate CAN CTRL VSV Press the right or left button CHECK Check the VSV operation when it is operated by the hand held tester OK VSV is ON Air does not flow from port E to port F VSV is OFF Air from port E flows out through port F OK Go to step 13 NG 10 Check vacuum hose between CCV and charcoal canister CHECK a Check that the vacuum hose is connected correctly b Check the vac...

Page 433: ...lve PREPARATION a Turn the ignition switch ON and push the hand held tes ter main switch ON b Select the ENHANCED OBD II ACTIVE TEST mode on the hand held tester c Select the item TANK BYPASS VSV ALL in the AC TIVE TEST and operate TANK BYPASS VSV Press the right or left button d Check the VSV operation when it is operated by the hand held tester CHECK Check the VSV operation when it is operated b...

Page 434: ...hing valve and pressure switching valve and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 16 Check whether hose close to fuel tank has been modified and check whether there are signs of any accident near fuel tank CHECK Check for cracks deformation and loose connection of the fol lowing parts S Fuel tank S Fuel tank filler pipe S Hoses and tubes around ...

Page 435: ... OK 18 Check hose and tube between fuel tank and charcoal canister CHECK a Check for proper connection of the fuel tank and fuel evap pipe See page EC 2 fuel evap pipe and fuel tube under the floor fuel tube under the floor and charcoal canister b Check the hose and tube for cracks hole and damage NG Repair or replace hose and tube OK 19 Check voltage between terminals VC and E2 of ECM connector C...

Page 436: ...or pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor NOTICE Vacuum applied to vapor pressure sensor must be less than 66 7 kPa 500 mmHg 19 7 in Hg OK Condition 1 Voltage 2 9 to 3 7 V Condition 2 Voltage 0 5 V or less OK Go to step 22 NG 21 Check for open and short in harness and connector between vapor pressure sens...

Page 437: ...GNOSTICS ENGINE 1ZZ FE 2005 CELICA RM1131U 23 Check fuel tank NG Replace fuel tank OK 24 Check charcoal canister for cracks hole and damage NG Repair or replace charcoal canister OK Replace ECM See page SF 78 436 ...

Page 438: ... Replace with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 437 ...

Page 439: ...tween vapor pressure sensor and fuel tank charcoal canister and pressure switching valve and pressure switching valve and char coal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks hole and damage NG Repair or replace vacuum hose OK 7 Check hose and tube between fuel tank and charcoal canis...

Page 440: ...s and disconnection c Check the vacuum hose for cracks hole damage and blockage NG Repair or replace vacuum hose OK 9 Check connector for EVAP VSV connector for CCV connector for pressure switching valve and vapor pressure sensor connector for looseness and discon nection NG Repair or connect or sensor connector OK 10 Check charcoal canister for cracks hole and damage NG Check and replace charcoal...

Page 441: ...PTNK and E2 of ECM connectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connectors at following condition 1 and 2 1 Disconnect the vacuum hose from the vapor pres sure sensor at following condition 1 and 2 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pres...

Page 442: ...ge SF 78 14 Check EVAP VSV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check VSV function 1 Connect between terminal EVP1 of the ECM con nector and body ground VSV ON 2 Disconnect between terminal EVP1 of the ECM connector and body ground VSV OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK Go to step 17 ...

Page 443: ... or connector OK Replace ECM See page SF 78 17 Check CCV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect between terminal CCV of the ECM con nector and body ground VSV ON 2 Disconnect between terminal CCV of the ECM con nector and body ground VSV OFF OK 1 VSV is ON Air does not flow from port E to port F 2 VSV is OFF Air from port E flows out...

Page 444: ... 78 20 Check pressure switching valve PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect between terminal TBP of the ECM connec tor and body ground VSV ON 2 Disconnect between terminal TBP of the ECM con nector and body ground VSV OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK ...

Page 445: ...EFI and pressure switching valve and pressure switching valve and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 23 Check fuel tank inlet valve NG Replace fuel tank inlet valve OK 24 Check fuel tank NG Replace fuel tank OK It is likely that vehicle user did not properly close fuel tank cap 444 ...

Page 446: ...tionary and there should be little variation in the tank pressure If the indicated pressure varies beyond specified limits the ECM will illuminate the MIL 2 trip detection logic and a DTC will be set The ECM checks for a stuck sensor by monitoring the fuel tank pressure for an extended time period If the indicated pressure does not change over this period the ECM will conclude that the fuel tank p...

Page 447: ... STRATEGY P0451 Related DTCs P0451 Evaporative emission control system pressure sensor range performance Required sensors components Main sensors components Vapor pressure sensor Related sensors components Mass air flow meter Engine coolant temperature sensor Frequency of operation Once per driving cycle Duration Fuel tank pressure sensor Noise monitor 10 sec Fuel tank pressure sensor Stuck monito...

Page 448: ...F Time after vehicle stop and idling 5 sec 15 sec Bypass VSV Closed Fuel tank pressure sensor Stuck monitor Altitude 2 400 m 7 872 ft Battery voltage 11 V Throttle position learning Completed Fuel tank temperature sensor malfunction P0452 P0453 Not detected Intake coolant temperature at engine start Engine coolant temperature at engine start 7_C 12 6_F 11 1_C 20_F EVAP VSV CCV bypass VSV Not opera...

Page 449: ...N PROCEDURE HINT S If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously terminal E2 may be open S If DTC P0441 Purge Flow P0446 CCV or P0451 Evaporative Pressure Sensor is output with DTC P0442 or P0456 troubleshoot DTC P0441 P0446 or P0451 first If no malfunction is detected trouble shoot DTC P0442 or P0456 next S Read freeze frame ...

Page 450: ...REPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connectors 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor 3 Check the vapor pressure sensor output waveform using a hand held tester NOTICE...

Page 451: ...S ENGINE 1ZZ FE 2005 CELICA RM1131U 3 Check for open and short in harness and connector between vapor pressure sensor and ECM See page IN 30 NG Repair or replace harness or connector OK Replace vapor pressure sensor 450 ...

Page 452: ...cle speed sensor signal to ECM 2 trip detection logic S Combination meter S Open or short in vehicle speed sensor circuit S Vehicle speed sensor S ECM MONITOR DESCRIPTION The ECM assumes that the vehicle is driven when over 30 sec have passed since the park neutral position switch was turned OFF If there is no signal from the vehicle speed sensor with these conditions satisfied the ECM concludes t...

Page 453: ...f the following conditions is met A or B A Following conditions are met a and b a Time after park neutral position switch turns from ON to OFF 10 sec b Engine coolant temperature 20 C 68 F B Following conditions are met a and b a Time after park neutral position switch turns from ON to OFF 30 sec b Engine coolant temperature 20 C 68 F Time after ignition SW is ON 2 sec Engine speed Vary with throt...

Page 454: ...f the operation of the speedmeter in the combination meter is normal HINT The vehicle speed sensor is operating normally if the speedometer display is normal NG Check speedometer circuit See combination meter troubleshooting See page BE 2 OK 2 Check voltage between terminal SPD of ECM connector and body ground PREPARATION a Remove the ECM cover b Shift the shift lever to neutral c Jack up one of t...

Page 455: ... IAC valve through the passage In this way the intake air volume bypassing the throttle valve is regulated controlling the engine speed The ECM operates the IAC valve only to perform idle up and provide feedback for the target idling speed DTC No DTC Detecting Condition Trouble Area P0505 Idle air continues to vary greatly from target speed 2 trip detection logic S Open or short in idle air contro...

Page 456: ...losing the throttle valve using the ETCS The ECM con cludes that the idle speed control ECM function is malfunctioning if 1 the actual idle RPM varies more than the specified amount or 2 a learning value of the idle speed control remains at the maximum or minimum five times or more during a driving cycle The ECM will turn on the MIL and set a DTC Example If the RPM difference between the target an...

Page 457: ...m h 1 9 mph Engine speed 400 rpm P0511 Output signal duty 10 90 Battery voltage 10V Time after first missing of voltage change 10 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0505 Functional check Following conditions are met At idle After running at more than 10 km h 6 2 mph per trip Conditions 1 2 and 3 1 Either of the following conditions is met Condition a or b a Deviation ...

Page 458: ...e throttle position is slightly opened the accelerator pedal is slightly depressed because a floor carpet is overlapped on the accelerator pedal or if not fully releasing the accelerator pedal etc DTC P505 will possibly be detected S Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubles...

Page 459: ...s DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF CHECK Read the DTCs RESULT Display DTC Output Proceed to P0505 and P0511 A P0505 P0511 and other DTCs B HINT If any other codes besides P0505 and P0511 are output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 42 A 2 Check connection of PCV piping NG Repair or replace PCV piping OK 3 Check air induction system C...

Page 460: ...d tester to the DLC3 f Enter the following menus DIAGNOSIS ENHANCED OBD ll ACTIVE TEST ISC DUTY RATIO CHECK Check that the engine RPM varies when changing the ISC duty ratio OK Engine PRM fluctuates up and down in response to the ISC duty ratio variation OK Check for intermittent problems See page DI 3 NG 5 Check A C signal circuit NG Repair or replace A C signal circuit OK 6 Check blockage of IAC...

Page 461: ...IAC valve connector b Turn the ignition switch ON CHECK Measure the voltage between the terminals VISC and IAC of IAC valve connector OK Voltage 9 to 14 V NG Repair or replace harness or connector OK 8 Check for open and short in harness and connector between IAC valve and ECM See page IN 30 NG Repair or replace harness or connector OK 9 Check IAC valve See page SF 48 NG Replace IAC valve Ok Repla...

Page 462: ...ping NG Repair or replace PCV piping OK 2 Check air induction system CHECK Check the air induction system vacuum leaks NG Repair or replace air induction system OK 3 Check A C signal circuit NG Repair or replace A C signal circuit OK 4 Check blockage of IAC valve and passage to bypass throttle valve NG Replace IAC valve OK 461 ...

Page 463: ...IAC valve connector b Turn the ignition switch ON CHECK Measure the voltage between the terminals VISC and IAC of IAC valve connector OK Voltage 9 to 14 V NG Repair or replace harness or connector OK 6 Check for open and short in harness and connector between IAC valve and ECM See page IN 30 NG Repair or replace harness or connector OK 7 Check IAC valve See page SF 48 NG Replace IAC valve OK Repla...

Page 464: ...on Trouble Area P0560 Open in back up power source circuit S Open in back up power source circuit S EFI fuse S ECM HINT If DTC P0560 is present the ECM will not store other DTC MONITOR STRATEGY Related DTCs P0560 System voltage malfunction Required sensors components ECM Frequency of operation Continuous Duration 3 sec MIL operation Immediate 1 Sequence of operation None 1 The DTC is set immediate...

Page 465: ...records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check EFI fuse PREPARATION Remove the EFI fuse from the engine room J B CHECK Check continuity of EFI ...

Page 466: ...e the ECM cover CHECK Measure voltage between terminal BATT of the ECM connector and body ground OK Voltage 9 to 14 V OK Check for intermittent problems See page DI 3 NG 3 Check for open and short in harness and connector between ECM and EFI fuse EFI fuse and battery See page IN 30 NG Repair or replace harness or connector OK Check and replace engine room J B 465 ...

Page 467: ...e revolution greater than 1 000 rpm c STA signal ON S Short in Park Neutral position switch circuit A T S Park Neutral position switch A T S Clutch start switch M T S ECM MONITOR STRATEGY Related DTCs P0617 Starter signal error Required sensors components Main sensors components Starter signal Related sensors components Vehicle speed sensor Engine speed sensor Frequency of operation Continuous Dur...

Page 468: ... 2F 2B ST AM2 MAIN FL MAIN W B B W B W IE1 1 4 5 Ignition Switch B R IK IC 11 9 IE4 EA1 4 1 EA1 14 W B B W B 1 1 2 B W B W B W W B W B IC1 3 6 IC1 B R W B 1 2 2 J3 J C IE A S1 S2 1 1 Park Neut ral Position Switch Clutch Start Switch Starter P1 I10 C11 1 A T 2 M T 9 6 1 2 ST2 AM2 2 1 DIAGNOSTICS ENGINE 1ZZ FE DI 269 2005 CELICA RM1131U WIRING DIAGRAM 467 ...

Page 469: ... tester 1 Check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD ll DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter is operating OK Ignition Switch Position ON START STA Signal OFF ON OK Go to step 5 NG 2 Check ...

Page 470: ...2 4 6 7 8 Below 1 Ω NG Replace ignition switch Go to next step 5 after the replacement OK 4 Check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD ll DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter is operating ...

Page 471: ... held tester main switch ON c Clear DTC See page DI 3 Enter the following menus DIAGNOSIS ENHANCED OBD ll DTC INFO CLEAR CODE and press YES d Drive the vehicle more than 40 km h 25 mph for 20 seconds or more CHECK Check the DTC reoccur RESULT Display DTC Output Proceed to P0617 A No DTC output B A Replace ECM See page SF 78 B Check for intermittent problems See page DI 3 470 ...

Page 472: ... the voltage between terminal STA of the ECM connec tor and body ground during the engine cranking OK Voltage 0 V Ignition switch ON 6 V or more Engine cranking OK Go to step 5 NG 2 Check park neutral position switch or clutch start switch a Inspect the park neutral position switch A T See page DI 789 b Inspect the clutch start switch M T See page CL 2 NG Replace park neutral position switch or cl...

Page 473: ...ss ON 2 3 4 6 7 1 Ω or less START 1 2 4 6 7 8 1 Ω or less NG Replace ignition switch Go to next step 5 after the replacement OK 4 Check voltage between terminal STA of ECM connector and body ground PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminal STA of the ECM connec tor and body ground during the engine cranking OK Voltage 0 V Ignition s...

Page 474: ...Turn the ignition switch ON and push the OBD II scan tool main switch ON c Clear DTC See page DI 3 d Drive the vehicle more than 40 km h 25 mph for 20 seconds or more CHECK Check DTC reoccur RESULT Display DTC Output Proceed to P0617 A No DTC output B A Replace ECM See page SF 78 B Check for intermittent problems See page DI 3 473 ...

Page 475: ...ot accurate ECM MONITOR STRATEGY Related DTCs P0630 VIN not programed Required sensors components Main sensors components ECM Related sensors components Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 3 Battery voltag...

Page 476: ... DTC NOTICE If P0630 is present the VIN must be input to the ECM using the hand held tester However all DTCs are cleared automatically by the tester when the VIN is input If DTCs other than P0630 are present check them first NEXT 2 Input VIN with hand held tester See page DI 29 NEXT END 475 ...

Page 477: ...No communication from body ECU b No communication from A C ECU S Body ECU S A C ECU S Communication bus INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was wa...

Page 478: ...it CIRCUIT DESCRIPTION When the ignition switch is turned ON battery voltage is applied to terminal IGSW of the ECM The ECM MREL output signal causes current to flow to the coil closing the contacts of the EFI relay and supplying power to terminal B of the ECM If the ignition switch is turned OFF the ECM holds the EFI relay ON for a maximum of 2 seconds to allow for the initial setting of the thro...

Page 479: ...on nector OK Voltage 9 to 14 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 39 NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminals IGSW and E1 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Me...

Page 480: ...y ACC 1 3 Continuity ON 1 2 3 5 6 Continuity START 1 2 4 5 6 Continuity NG Replace ignition switch OK Check and repair harness and connector between battery and ignition switch ignition switch and ECM See page IN 30 5 Check voltage between terminals MREL and E1 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure voltage between terminals MREL and E1 of t...

Page 481: ...ck continuity of EFI fuse OK Continuity NG Check for short in all the harness and compo nents connected to EFI fuse OK 7 Check EFI No 1 fuse PREPARATION Remove EFI No 1 fuse from engine room J B CHECK Check continuity of EFI No 1 fuse OK Continuity NG Check for short in all the harness and compo nents connected to EFI No 1 fuse OK 8 Check EFI main relay Marking EFI See page SF 56 NG Replace EFI ma...

Page 482: ...open and short in harness and connector between EFI relay and ECM EFI relay and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace harness and connector between terminal B of ECM and battery positive ter minal See page IN 30 481 ...

Page 483: ...am below when the engine is cranked current flows from terminal ST2 of the ignition switch to the starter relay coil and also current flows to terminal STA of the ECM STA signal When the STA signal and NE signal are input to the ECM Tr is turned ON current flows to the coil of the circuit opening relay the relay switches on power is supplied to the fuel pump and the fuel pump operates While the NE...

Page 484: ...MREL FC 21 E3 L B G R EB 11 FL MAIN Battery 3 E2 12 2F 10 2F 11 2F C OPN Relay 1 EFI Relay W B EFI II2 L B 2 5 3 1 2 5 3 7 2H 1 2A 4 5 BJ L B B R F17 Fuel Pump A W B DIAGNOSTICS ENGINE 1ZZ FE DI 285 2005 CELICA RM1131U WIRING DIAGRAM 483 ...

Page 485: ...GNOSIS ENHANCED OBD II ACTIVE TEST FUEL PUMP SPD CHECK Check the relay operation while operating it with the hand held tester OK Operating noise can be heard from the relay OK Go to step 5 NG 2 Check circuit opening relay Marking C OPN See page SF 57 NG Replace circuit opening relay OK 3 Check voltage between terminal FC of ECM and body ground PREPARATION a Remove the ECM cover b Turn the ignition...

Page 486: ...PN and ignition switch See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 5 Check fuel pump See page SF 6 NG Repair or replace fuel pump OK 6 Check for open in harness and connector between circuit opening relay Mark ing C OPN and fuel pump fuel pump and body ground See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 485 ...

Page 487: ...nd body ground b Check for fuel pressure in the fuel inlet hose when it is pinched off OK There is pressure in fuel inlet hose HINT At this time you will hear a fuel return flowing noise OK Proceed to next circuit inspection shown on problem symptoms table See page DI 39 NG 2 Check operation of circuit opening relay Marking C OPN CHECK When connecting between terminal FC of the ECM connector and t...

Page 488: ...RATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure voltage between terminal FC of the ECM and body ground OK Voltage 9 to 14 V OK Replace ECM See page SF 78 NG 5 Check for open and short in harness and connector between circuit opening relay Marking C OPN and ECM circuit opening relay Marking C OPN and ignition switch See page IN 30 NG Repair or replace harness or connector ...

Page 489: ...ump See page SF 6 NG Repair or replace fuel pump OK 7 Check for open in harness and connector between circuit opening relay Mark ing C OPN and fuel pump fuel pump and body ground See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 488 ...

Page 490: ...n be read through the MIL flashing in the combination meter WIRING DIAGRAM INSPECTION PROCEDURE HINT S Even though terminal TC is not connected with terminal CG the MIL blinks S For the above phenomenon an open or short in the wire harness or malfunction inside the ECM is the likely cause 1 Check voltage between terminals TC and CG of DLC3 PREPARATION Turn the ignition switch ON CHECK Measure the ...

Page 491: ...n terminal CG of DLC3 and body ground NG Repair or replace harness or connector OK 3 Check for open and short circuit in harness and connector between ECM and DLC3 and DLC3 and body ground See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 490 ...

Page 492: ...20 Basic Inspection P DI 295 DTC Chart P DI 335 Problem Symptoms Table P DI 332 Circuit Inspection P DI 344 Adjustment Repair DTC Check P DI 295 Items inside are titles of pages in in the bottom portion See the indicated pages for detailed explanations this manual with the page number Malfunction occurs Malfunction does not occur Parts Inspection Check for Intermittent Problems P DI 295 Identifica...

Page 493: ...D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temp Place Outdoor Temperature Constant Sometimes times per day month Once only Other Fine Cloudy Rainy Snowy Various Other Hot Warm Cool Cold approx C F Highway Suburbs Inner city Uphill Downhill Rough road Other Cold Warming up After warming up Any temp Other Starting Just after startin...

Page 494: ... the computer In addition the applica ble Diagnostic Trouble Codes DTCs prescribed by SAE J2012 are recorded in the ECM memory See page DI 335 If the malfunction does not reccur in 3 consecutive trips the MIL goes off automatically but the DTCs remain recorded in the ECM memory S To check the DTC connect the hand held tester or OBD II scan tool to the Data Link Connector 3 DLC3 of the vehicle The ...

Page 495: ...detected again the MIL will illumi nate This is known as 2nd trip detection S Freeze frame data The freeze frame data records the engine condi tions fuel system calculated load engine coolant temperature fuel trim engine speed vehicle speed etc when a malfunction is detected When troubleshooting freeze frame data can help deter mining if the vehicle was running or stopped if the engine was warmed ...

Page 496: ... screen displays UNABLE TO CONNECT TO VEHICLE a problem exists in the vehicle side or the tester side S If the communication is normal when the tool is connected to another vehicle inspect the DLC3 on the original ve hicle S If the communication is still impossible when the tool is connected to another vehicle the problem is probably in the tool itself so consult the Service Department listed in t...

Page 497: ... ON 3 Use the OBD II scan tool or the hand held tester to check the DTCs and freeze frame data and then write them down For the hand held tester enter the following me nus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES For the OBD II scan tool see its instruction manual 4 See page DI 295 to confirm the details of the DTCs NOTICE When simulating a symptom with the OBD II scan tool ex cluding hand...

Page 498: ...conds After disconnecting the battery terminal perform the INI TIALIZE procedure 3 DTC CHECK Check Mode HINT Hand held tester only Check mode has a higher sensitivity to detect malfunctions and can detect malfunctions that normal mode cannot detect Check mode can also detect all the malfunctions that normal mode can detect a Follow these steps when preparing to use the hand held tester check mode ...

Page 499: ... OBD II DTC INFO CLEAR CODES and 2 press YES For the OBD II scan tool see its instruction manual c Clear the DTCs without using the OBD ll scan tool or the hand held tester Remove the EFI and ETCS fuses from the engine room J B for more than 60 seconds or disconnect the battery terminal for more than 60 seconds After disconnecting the battery terminal perform the INI TIALIZE procedure 4 FAIL SAFE ...

Page 500: ...1 P2122 P2123 P2125 P2127 P2128 P2138 The accelerator pedal position sensor has two main and sub sensor circuits If a malfunction occurs in either of the sensor circuits the ECM detects the abnormal signal volt age difference between the two sensor circuits and switches to limp mode In limp mode the remaining circuit is used to calculate the accelerator pedal opening to allow the vehicle to contin...

Page 501: ... location causing the problem can be found quickly and efficiently There fore using this check is essential in the engine troubleshooting 1 Is battery positive voltage 11 V or more when engine is stopped NO Charge or replace battery YES 2 Is engine cranked NO Proceed to page ST 15 and ST 17 and contin ue to troubleshoot YES 3 Does engine start NO Go to step 6 YES 4 Check air filter PREPARATION Rem...

Page 502: ...e DI 332 OK 6 Check fuel pressure PREPARATION a Be sure that enough fuel is in the tank b Connect the hand held tester to the DLC3 c Turn the ignition switch ON and push the hand held tes ter main switch ON d Use ACTIVE TEST mode to operate the fuel pump HINT Please refer to the hand held tester operator s manual for fur ther details e If you have no hand held tester connect the positive and negat...

Page 503: ...ition coil assembly d Disconnect the injector connector e Ground the spark plug CHECK Check if spark occurs while engine is being cranked NOTICE To prevent excess fuel being injected from the injectors during this test don t crank the engine for more than 5 10 seconds at a time NG Proceed to page IG 1 and continue to trouble shoot OK Proceed to problem symptoms table on page DI 332 502 ...

Page 504: ... control valve duty ratio Opening ratio rotary solenoid type ISC valve Min 0 Max 99 Idling 25 to 45 Running without load 2 500 rpm 25 to 45 CALC LOAD Calculated load by ECM Min 0 Max 100 Idling 9 1 to 20 0 Running without load 2 500 rpm 11 0 to 23 0 MAF Air flow rate from MAF sensor Min 0 gm s Max 655 gm s Idling 1 5 to 5 0 gm s Racing without load 2 500 rpm 5 0 to 15 0 gm s If the value is approx...

Page 505: ... 100 Max 100 0 20 Same as SHORT FT 1 O2FT B1 S2 Short term fuel trim associated with the bank 1 sensor 2 Min 100 Max 100 0 20 Same as SHORT FT 2 FUEL SYS 1 Fuel system status Bank 1 OL or CL or OL DRIVE or OL FAULT or CL FAULT Idling after warming up CLOSED S OL Open loop has not yet satis fied conditions to go closed loop S CL Closed loop using heated ox ygen sensor s as feed back for fuel contro...

Page 506: ...Engine RPM for first misfire range Min 0 rpm Max 6 375 rpm Misfire 0 0 rpm O2 LR B1 S2 Response time of the heated oxy gen sensor lean to rich bank 1 sensor 2 Min 0 ms Max 16 711 ms Idling after warming up 0 to 1 000 m s FC TAU Fuel cut TAU Fuel cut during very light load Fuel cut operating ON The fuel cut is performed under very light load to prevent the en gine combustion from becoming incomplet...

Page 507: ...s S All injectors are tested at once S Injection volume is gradual ly changed between 12 5 and 25 A F CONTROL Test Details Control the injection volume 12 5 or 25 Change the injection volume 12 5 or 25 Vehicle Condition Engine speed 3 000 rpm or less The following A F CON TROL procedure enables the technician to check and graph the voltage outputs of both the A F sensor and heated oxygen sensor Fo...

Page 508: ...ts that are used by the ECM to detect malfunctions Frequency of operation The number of times that the ECM checks for malfunctions per driving cycle Once per driving cycle means that the ECM detects the malfunction only one time during a single driving cycle Continuous means that the ECM detects malfunction every time an enabling condition is met Duration The minimum time that the ECM must sense a...

Page 509: ...ratio sensor O2 sensor Heater oxygen sensor Oxygen sensor pumping current circuit Oxygen sensor output signal Oxygen sensor reference ground circuit Oxygen sensor signal ground Accel position sensor Accelerator pedal position sensor Throttle actuator control motor Actuator control motor Elec tronic throttle motor Throttle control motor Electronic throttle actuator Electronic throttle control syste...

Page 510: ...DI 311 2005 CELICA RM1131U Shift solenoid Transmission shift solenoid valve Transmission control switch Shift lock control unit Shift lock control module Engine immobiliser system Immobiliser system Vehicle anti theft system 509 ...

Page 511: ...RM1131U 11 The monitor will run whenever the following DTCs are not present Monitor disablement List HINT The table below shows the ECM monitoring status for the components listed at the top of the table when the DTCs on the left of the table are set 510 ...

Page 512: ...A21571 DIAGNOSTICS ENGINE 2ZZ GE DI 313 2005 CELICA RM1131U 511 ...

Page 513: ...A21572 DI 314 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 512 ...

Page 514: ...A21573 DIAGNOSTICS ENGINE 2ZZ GE DI 315 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 513 ...

Page 515: ...A21575 DI 316 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 514 ...

Page 516: ...A21576 DIAGNOSTICS ENGINE 2ZZ GE DI 317 2005 CELICA RM1131U Note 1 Without input the speed sensor Note 2 With input the speed sensor 515 ...

Page 517: ...manual the description of the O2S TEST RESULT for O2S related DTCs are written in a table This table consists of 5 items 1 TEST ID a code applied to each TEST DATA 2 Description of TEST DATA 3 Conversion Factor When Conversion Factor has a value written in the table multiply the TEST DATA value appearing on the scan tool by the Conversion Factor value The result will be the required value 4 Unit 5...

Page 518: ...ays 17 as a value of the TIME 81 see the illustration on the left 2 Find the Conversion Factor value of TIME 81 in the O2S TEST RESULT chart below 0 3906 is spe cified for 81 in this chart 3 Multiply 17 in step 1 by 0 3906 Conversion Fac tor in the step 2 17 x 0 3906 6 6 4 If the answer is within the standard value the TIME 81 can be confirmed to be normal O2S TEST RESULT Chart TEST ID Description...

Page 519: ... the component is functioning normally or not The test value is the value that was used to determine the monitor result If the test value is outside the test limit mal function criterion the ECM determines the component is malfunctioning Some emissions related components have multiple test values to determine monitor result If one of these test values is outside test limit the ECM determines the c...

Page 520: ...S INCMP indicates the component has not been monitored yet S PASS indicates the component is functioning normally S FAIL indicates the component is malfunction ing 6 Select the component and press ENTER If the monitor result has been PASS or FAIL the accuracy test value appears S VAL indicates the test value S LMT indicates the test limit malfunction crite rion S TLT indicates the test limit type ...

Page 521: ...do not match the VIN can be registered or overwritten in the ECM by following this procedure 2 INPUT INSTRUCTIONS a Hand held tester The arrow buttons UP DOWN RIGHT and LEFT and numerical buttons 0 to 9 are used in order to input the VIN b Cursor Operation To move the cursor around the tester screen press the RIGHT and LEFT buttons c Alphabetical Character Input 1 Press the UP and DOWN buttons to ...

Page 522: ...ogrammed or Mismatch ECM PCM Please input the VIN PRESS EXIT Possible cause To Menu Screen 17 digitVIN displayed 3 Select VIN DTC P0630 Set VIN Previously Stored VIN Not Stored EXIT EXIT EXIT 2 VIN WRITE VIN Select VIN READ 1 VIN READ 1 VIN READ ERROR ECM does not respond the VIN 1 VIN is not written yet 2 Vehicle does not support this function DIAGNOSTICS ENGINE 2ZZ GE DI 323 2005 CELICA RM1131U ...

Page 523: ... Continuedon next page NOTICE Do you wish to continue YES NO 1 Select DIAGNOSIS 2 Select ENHANCED OBD ll 3 Select VIN 1 VIN READ 1 VIN READ VIN Select VIN WRITE YES or NO YES 2 VIN WRITE To Menu Screen NO CONFIRMATION This function will erase the DTCs automatically after writing the VIN Do you wish to continue YES 17 digit VIN displayed VIN Previously Stored DI 324 DIAGNOSTICS ENGINE 2ZZ GE 2005 C...

Page 524: ...ror SET NEW VIN Press RIGHT LEFT to shift the cursor right left Press UP DOWN to increase decrease value Or input digit with the 10 key PRESS ENTER CONFIRMATION PRESS ENTER Vehicle is stopped New Registration ENTER ENTER PRESS ENTER Communication Error ENTER COMMUNICATION ERROR PRESS EXIT Turn IG OFF then ON VIN input method The following VIN has been written correctly The DTCs have been erased co...

Page 525: ...us of complete indicates that the necessary conditions have been met to run the performance tests for the related Readiness Monitor S The Readiness Monitor will be reset to incomplete if S ECM has lost power battery or fuse S DTCs have been cleared S The conditions for running the Readiness Monitor have not been met S In the event that any Readiness Monitor shows incomplete follow the appropriate ...

Page 526: ...us and preconditions 2 Drive the vehicle at 40 to 55 mph 64 to 88 km h for approximately 3 minutes NOTICE Drive with smooth throttle operation and avoid sudden acceleration If IAT is less than 10 C 50 F when engine was started drive the vehicle at 40 to 55 mph 64 to 88 km h for additional 4 minutes 3 Drive the vehicle at 35 to 45 mph 56 to 72 km h for approximately 7 minutes NOTICE Drive with smoo...

Page 527: ...MIL is OFF S Fuel level is approximately 1 2 to 3 4 S Altitude is 7 800 feet 2 400m or less b Cold Soak Procedure Let the vehicle cold soak for 8 hours or until the difference between IAT and ECT becomes less than 7 C 13 F HINT Examples S Scenario 1 ECT 24 C 75 F IAT 16 C 60 F Difference between ECT and IAT is 8 C 15 F The monitor will not run because difference between ECT and IAT is greater than...

Page 528: ...monitor will run because difference between ECT and IAT is less than 7 C 13 F The readiness test can be completed in cold ambient conditions less than 40 F 4 4 C and or at high altitudes more than 7 800 feet 2 400 m if the drive pattern is repeated a second time after cycl ing the ignition off b Drive Pattern 1 Connect the OBDII scan tool to DLC3 to check monitor status and preconditions refer to ...

Page 529: ...rn 1 Connect the OBDII scan tool to DLC3 to check monitor status and preconditions refer to a 2 Start the engine and allow it to idle for 2 minutes or more 3 Drive the vehicle at 25 mph 40 km h or more for at least 50 seconds 4 Stop the vehicle and allow the engine to idle for 40 seconds or more 5 Perform steps 3 and 4 ten times 6 Check the status of the readiness monitor on the scan tool display ...

Page 530: ...n 1 Connect the OBDII scan tool to the DLC3 to check monitor status and preconditions refer to a 2 Start the engine and allow it to idle for 500 seconds or more 3 Drive the vehicle at 25 mph 40 km h or more for at least 2 minutes 4 Check the status of the readiness monitor on the scan tool display If readiness status did not switch to complete ensure the preconditions are met turn the ignition off...

Page 531: ...rol circuit DI 571 DI 656 Difficult to start with hot engine 1 Starter signal circuit 2 Fuel pump control circuit DI 571 DI 656 High engine idle speed Poor idling 1 A C switch circuit 2 ECM power source circuit DI 652 Low engine idle speed Poor idling 1 A C switch circuit 2 Fuel pump control circuit DI 656 Rough idling Poor idling 1 Compression 2 Fuel pump control circuit EM 3 DI 656 Hunting Poor ...

Page 532: ... E9 18 E1 E12 1 W BR During transmission Pulse generation PTNK E9 21 E2 E10 28 L B BR Ignition switch ON 2 9 to 3 7 V Apply vacuum 4 0 kPa 30 mmHg 1 18 in Hg Below 0 5 V VPA E9 22 EPA E9 28 L Y L R IG switch ON Accelerator pedal released 0 3 to 0 9 V IG switch ON Accelerator pedal depressed 3 2 to 4 8 V VPA2 E9 23 EPA2 E9 29 L O LG R IG switch ON Accelerator pedal released 1 8 to 2 7 V IG switch O...

Page 533: ...Y G Idling P or N range A C switch OFF 0 5 to 3 0 V 10 E10 1 E01 E10 7 20 E10 2 E01 E10 7 30 E10 3 E01 E10 7 40 E10 4 E01 E10 7 L R W B L O W B L B W B L W B IG switch ON 9 to 14 V Idling Pulse generation See page DI 459 IGT1 E10 8 E1 E12 1 IGT2 E10 9 E1 E12 1 IGT3 E10 10 E1 E12 1 IGT4 E10 11 E1 E12 1 R G BR GR R BR G R BR R Y BR Idling Pulse generation See page DI 486 VC E10 18 E2 E10 28 R B BR I...

Page 534: ...rcuit Low Bank 1 Sensor 1 S Open in heater circuit of heated oxygen sensor S Heated oxygen sensor heater S EFI relay S ECM f f P0032 DI 360 Oxygen Sensor Heater Control Circuit High Bank 1 Sensor 1 S Short in heater circuit of heated oxygen sensor S Heated oxygen sensor heater S EFI relay S ECM f f P0037 DI 360 Oxygen Sensor Heater Control Circuit Low Bank 1 Sensor 2 S Open in heater circuit of he...

Page 535: ...r S ECM f f P0121 DI 402 Throttle Pedal Position Sensor Switch A Circuit Range Perfor mance Problem S Throttle position sensor f f P0122 DI 391 Throttle Pedal Position Sensor Switch A Circuit Low Input S Throttle position sensor S VC circuit open S VTA1 circuit short S ECM f f P0123 DI 391 Throttle Pedal Position Sensor Switch A Circuit High Input S Throttle position sensor S VTA1 circuit open S E...

Page 536: ...ature sensor S Fuel pressure S Gas leakage in exhaust system S Open or short in heated oxygen sensor bank 1 sensor 1 circuit S Heated oxygen sensor bank 1 sensor 1 S Heated oxygen sensor heater bank 1 sensor 1 S EFI relay S PCV valve and hose S PCV hose connection S ECM f f P0172 DI 446 System too Rich Bank 1 S Injector leak blockage S Mass air flow meter S Engine coolant temperature sensor S Igni...

Page 537: ...ankshaft Position Sensor A Circuit Intermittent S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Signal plate S ECM f f P0340 DI 482 Camshaft Position Sensor A Circuit Bank 1 or Single Sensor S Open or short in camshaft position sensor circuit S Camshaft position sensor S Camshaft timing pulley S Timing chain has a jumped tooth S ECM f f P0341 DI 482 Camshaft Po...

Page 538: ...nnected 1 2 3 4 5 6 7 8 9 10 and 11 in Fig 1 S Open or short in vapor pressure sensor circuit S Vapor pressure sensor S Open or short in VSV circuit for EVAP S EVAP VSV S Open or short in VSV circuit for CCV S CCV S Open or short in VSV circuit for pressure switching valve S Pressure switching valve S Fuel tank is cracked or damaged S Charcoal canister is cracked or damaged S Fuel tank over fill c...

Page 539: ...switch M T S Starter relay S Ignition switch S ECM f f P0630 DI 579 VIN not Programmed or Mis match ECM PCM S ECM f f P0657 DI 569 Actuator Supply Voltage Circuit Open S ECM f f P1645 DI 581 Body ECU Malfunction S Body ECU S A C ECU S Communication bus f f P2102 DI 582 Throttle Actuator Control Motor Circuit Low S Open in throttle control motor circuit S Throttle control motor S ECM f f P2103 DI 5...

Page 540: ... pedal position sensor S Open in EPA2 circuit S ECM f f P2135 DI 391 Throttle Pedal Position Sensor Switch A B Voltage Correla tion S VTA1 and VTA2 circuit are short circuited S Throttle position sensor S ECM f f P2138 DI 597 Throttle Pedal Position Sensor Switch D E Voltage Correla tion S VPA and VPA2 circuit are short circuited S Accelerator pedal position sensor S ECM f f P2195 DI 411 Oxygen Se...

Page 541: ... S Air pump fuse S Vacuum hose S Air pump assembly S Open in air pump circuit S Secondary air injection system piping S Pressure sensor S Open or short in pressure sensor circuit S ECM f f P2645 DI 640 OCV for VVTL Circuit Bank 1 S Open or short in oil control valve circuit S Oil control valve for VVT L S Oil pressure switch for VVT L S ECM f f P2646 DI 645 OCV for VVTL Close Malfunction Bank 1 S ...

Page 542: ...AP A T PNP Switch Injector Camshaft Position Sensor VSV for CCV VSV for Intake Air Control VSV for Pressure Switing Valve OCV for VVL PS Oil Pressure Sensor Oil Pressure Switch for VVL Throttle Position Sensor S S Throttle Control Motor Air Pump Assembly Air Switching Valve Air Pump Relay Engine Room J B D Circuit Opening Relay D ST Relay D EFI Fuse D ST Relay D EFI Relay D EFI No 1 Fuse D EFI No ...

Page 543: ...ure The ECM controls the OCV based on the signals output from the sensors The VVT controller regulates the intake camshaft angle using oil pressure through the OCV As a result the relative position between the cam shaft and the crankshaft is optimized and the engine torque and fuel economy improve and exhaust emis sions decrease under overall driving conditions Also the ECM detects the actual valv...

Page 544: ...imum The monitor will run whenever this DTC is not present See page DI 295 Battery Voltage 11 V 13 V Target duty ratio 70 Starter OFF Current cut status Not cut TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following condition is met A or B A Output signal duty for OCV Output duty ratio is 100 always ON but target duty ratio is less than 70 B Output signal duty for OCV ...

Page 545: ...ARATION a Connect the hand held tester to the DLC3 b Start the engine and warm it up c Turn the ignition switch ON and push the hand held tester main switch ON d Enter the following menus DIAGNOSIS ENHANCED OBD II ACTIVE TEST VVT CTRL B1 CHECK Check the engine speed when operating the OCV by the hand held tester OK Tester Operation Specified Condition OCV is OFF Normal engine speed OCV is ON Rough...

Page 546: ... ENGINE 2ZZ GE DI 347 2005 CELICA RM1131U 3 Check for open and short in harness and connector between OCV and ECM See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page SF 78 545 ...

Page 547: ...ine and warm it up b Disconnect the OCV connector c Apply battery voltage between the terminals of the OCV CHECK Check the engine speed OK Rough idle or engine stalled NG Replace OCV OK 2 Check for open and short in harness and connector between OCV and ECM See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page SF 78 546 ...

Page 548: ...lve Timing system to control the intake valve camshaft The VVT system includes the ECM the OCV Oil Control Valve and the VVT controller The ECM sends a target duty cycle control signal to the OCV This control signal sent to the OCV regulates the oil pressure applied to the VVT controller The VVT controller can advance or retard the intake valve camshaft Example A DTC will be set if 1 the differenc...

Page 549: ...not change WIRING DIAGRAM Refer to DTCs P0010 on page DI 344 INSPECTION PROCEDURE HINT Advanced timing over Valve timing is out of specified range P0011 Retarded timing over Valve timing is out of specified range P0012 Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze ...

Page 550: ...al engine speed OCV is ON Rough idle or engine stall NG Go to step 4 OK 3 Check if DTC output reoccurs PREPARATION a Clear the DTCs 1 Operating the hand held tool to erase the codes or disconnect the battery terminal or remove the EFI fuse for more than 60 seconds b Start and warm up the engine c Drive the vehicle around for 10 minutes or more CHECK Read output DTCs using the hand held tool OK No ...

Page 551: ...valve filter OK 5 Check oil control valve See page SF 54 OK Go to step 7 NG 6 Replace oil control valve Go 7 Check VVT controller assembly See page EM 50 OK Go to step 9 NG 8 Replace VVT controller assembly See page EM 44 Go 9 Check blockage of OCV oil check valve and oil pipe No 1 NG Repair or replace OK 550 ...

Page 552: ...for more than 60 seconds b Start and warm up the engine c Drive the vehicle around for 10 minutes or more CHECK Read output DTC using the hand held tester OK No DTC output OK VVT system is OK DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system These codes will stay even if the system returns to normal after a short time Foreign objects are filtered out by the ...

Page 553: ...ed tooth of timing chain See page EM 26 NG Adjust valve timing OK 2 Check operation of OCV PREPARATION Start the engine CHECK a Check the engine speed when disconnecting the OCV connector b Check the engine speed when applying battery voltage between the terminals of the OCV RESULT Result Check a Check b 1 Normal engine speed Rough idle or engine stall 2 Except 1 2 Go to step 4 1 552 ...

Page 554: ...cle around for 10 minutes or more CHECK Read output DTCs using the OBD II scan tool OK No DTC output OK VVT system OK DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system These codes will stay even if the system returns to normal after a short time Foreign objects are filtered out by the oil filter NG 4 Check oil control valve filter NG Replace oil control valv...

Page 555: ...ZZ GE 2005 CELICA RM1131U 7 Check VVT controller assembly See page EM 50 OK Go to step 9 NG 8 Replace VVT controller assembly See page EM 44 Go 9 Check blockage of OCV oil check valve and oil pipe No 1 NG Repair or replace OK 554 ...

Page 556: ...for more than 60 seconds b Start and warm up the engine c Drive the vehicle around for 10 minutes or more CHECK Read output DTC using the OBD II scan tool OK No DTC output OK VVT system is OK DTCs P0011 and P0012 are output when a foreign object in the engine oil enters the system These codes will stay even if the system returns to normal after a short time Foreign objects are filtered out by the ...

Page 557: ...The ECM stores this value as VVT learning value When the difference between the target valve timing and the actual valve timing is 5 degrees or less the ECM stores this in its memory If the learning value meets both of the following conditions a and b the ECM interprets this as a defect in the VVT system and sets a DTC a VVT learning value is less than 19 CA crankshaft angle or more than 41 CA b A...

Page 558: ...itions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check valve timing Check for loosen and jumped tooth of timing chain NG Adjust valve timing Repair or replace timing chain OK...

Page 559: ...RCUIT DESCRIPTION Refer to DTC P0130 on page DI 411 HINT The ECM provides a pulse width modulated control circuit to adjust current through the heater The heated oxygen sensor heater circuit uses a relay on the B side of the circuit DTC No DTC Detection Condition Trouble Area P0031 P0037 Heater current is 0 25 A or less when heater operates with B greater than 11 5 V 1 trip detection logic S Open ...

Page 560: ...erating range the ECM interprets this as a fault in the heated oxygen sensor and sets a DTC Example The ECM will set a high current DTC if the current in the sensor is more than 2 A when the heater is OFF Similarly the ECM will set a low current DTC if the current is less than 0 25 A when the heater is ON MONITOR STRATEGY Related DTCs P0031 Heated oxygen sensor heater current bank 1 sensor 1 Low c...

Page 561: ...nt Less than 0 25 A at 0 2 sec after heater ON P0032 P0038 High current Heated oxygen sensor heater current More than 2 A while intrusive heating is OFF COMPONENT OPERATING RANGE Parameter Standard Value Heated oxygen sensor heater current under following condi tions S Engine is idling S Heated oxygen sensor is warmed up S Battery voltage is 11 to 14 V 0 4 to 1 0 A MONITOR RESULT Refer to page DI ...

Page 562: ... HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Chec...

Page 563: ... and 2 NG Replace EFI relay OK 3 Check voltage between terminals HT1A HT2A HT1B HT2B of ECM connectors and body ground PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals HT1A HT2A HT1B HT2B of the ECM connectors and body ground HINT S Connect terminal HT1A to bank 2 sensor 1 S Connect terminal HT2A to bank 1 sensor 1 S Connect terminal HT1B...

Page 564: ...A RM1131U 4 Check for open and short in harness and connector between EFI main relay Marking EFI and heated oxygen sensor and heated oxygen sensor and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 563 ...

Page 565: ...M varies the voltage applied to these components in the MAF meter The voltage level is pro portional to the airflow through the sensor and the ECM interprets this voltage as the intake air amount The circuit is constructed so that the platinum hot wire and the temperature sensor provide a bridge circuit with the power transistor controlled so that the potential of A and B remains equal to maintain...

Page 566: ...lated DTCs P0100 Mass air flow meter circuit range check Fluttering P0102 Mass air flow meter circuit range check Low voltage P0103 Mass air flow meter circuit range check High voltage Required sensors components Mass air flow meter Frequency of operation Continuous Duration 3 sec MIL operation Immediate When engine speed is less than 4 000rpm 2 driving cycles When engine speed is 4 000 rpm or mor...

Page 567: ...MAIN EB GR 32 E11 24 G W 2 E2G B B R 3 VC 1 4 2C EFI No 1 Battery 3 2 5 1 1 2A 7 2H 12 2F MREL 8 E9 EFI Relay E11 DI 368 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U COMPONENT OPERATING RANGE Parameter Standard Value Mass air flow meter voltage 0 4 to 2 2 V WIRING DIAGRAM 566 ...

Page 568: ...ect OBD II scan tool or hand held tester and read value of mass air flow rate PREPARATION a Connect the OBD II scan tool or hand held tester to the DLC3 b Turn the ignition switch ON and push the OBD II scan tool or hand held tester main switch ON c Start the engine d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF CHECK Read the mass air flow rate...

Page 569: ...K Voltage 9 to 14 V NG Go to step 5 OK 3 Check voltage between terminal VG of ECM connector and body ground PREPARATION a Remove the ECM cover b Start the engine CHECK Measure the voltage between terminal VG of the ECM connec tor and body ground while the engine is idling OK Voltage 1 1 to 1 5 V P or N position and A C switch OFF OK Replace ECM See page SF 78 NG 4 Check for open and short in harne...

Page 570: ... circuit See page DI 652 6 Check continuity between terminal EVG of ECM connector and body ground PREPARATION Remove the ECM cover CHECK Check the continuity between terminal EVG of the ECM con nector and body ground OK Continuity 1 Ω or less NG Replace ECM See page SF 78 OK 7 Check for open in harness and connector between mass air flow meter and ECM See page IN 30 NG Repair or replace harness or...

Page 571: ... platinum wire exposed to the flow of intake air By applying a specific current to the wire the ECM heats this wire to a given temperature The flow of incoming air cools the wire and an internal thermistor changing their resistance To maintain a constant current value the ECM varies the volt age applied to these components in the MAF meter The voltage level is proportional to the air flow through ...

Page 572: ...ltage 4 9 V Engine coolant temperature 70_C 158_F Low voltage Engine RPM 300 rpm MAF meter voltage 0 2 V Fuel cut OFF TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold High voltage Mass air flow meter voltage More than 2 2 V varies with throttle position sensor voltage Low voltage Mass air flow meter voltage Less than 0 65 V varies with throttle position sensor voltage WIRING DIAGRAM Ref...

Page 573: ...ime when a malfunction occurred 1 Are there any other codes besides DTC P0101 being output PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT...

Page 574: ...nal THA THAR via re sistor R That is the resistor R and the intake air temperature sensor are connected in series When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature the potential at terminal THA THAR also changes Based on this signal the ECM increases the fuel injection volume to improve the driveability during cold engin...

Page 575: ...take air temperature sensor Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page DI 295 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0110 Intake air temperature sensor resistance Intake air te...

Page 576: ...A15651 ECM M1 Intake Air Temperature Sensor Built into Mass Air Flow Meter 4 5 Y R 5 V THA 20 R E10 BR 28 E2 E1 E10 THA E2 DIAGNOSTICS ENGINE 2ZZ GE DI 377 2005 CELICA RM1131U WIRING DIAGRAM 575 ...

Page 577: ...ake air tem perature PREPARATION a Connect the OBD II scan tool or hand held tester to the DLC3 b Turn the ignition switch ON and push the OBD II scan tool or hand held tester main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA INTAKE AIR CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Same as actual int...

Page 578: ...connector b Connect the sensor wire harness terminals together c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA INTAKE AIR CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK re place mass air flow meter NG 57...

Page 579: ...he following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA INTAKE AIR CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Repair or replace harness or connector NG Confirm good connection at ECM If OK re place ECM See page SF 78 4 Check for short in harness and ECM PREPARATION a Disconnect the mass air flow meter connector b ...

Page 580: ...0 connector from the ECM HINT The mass air flow meter connector is disconnected c Turn the ignition switch ON d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA INTAKE AIR CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Repair or replace harness or connector NG Replace ECM See page SF 78...

Page 581: ...t in engine coolant tem perature sensor circuit for 0 5 sec P0118 Step 2 Open in engine coolant tem perature sensor circuit for 0 5 sec HINT After confirming DTC P0115 P0117 or P0118 use the OBD II scan tool or the hand held tester to confirm the engine coolant temperature from the DIAGNOSIS ENHANCED OBD II DATA LIST ALL Displayed Temperature Malfunction 40 C 40 F Open circuit 140 C 284 F or more ...

Page 582: ...L operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS The monitor will run whenever these DTCs are not present See page DI 295 The typical enabling condition is not avail able TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold P0115 Engine coolant temperature sensor resistance coolant temperature Less than 79 Ω or more than 156 kΩ More than 140_C 284_F or less than ...

Page 583: ...FI6448 ECM 5 V THW E6 Engine Coolant Temperature Sensor 2 1 G BR E1 E2 E10 28 19 E10 DI 384 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U WIRING DIAGRAM 582 ...

Page 584: ...lant temperature PREPARATION a Connect the OBD II scan tool or hand held tester to the DLC3 b Turn the ignition switch ON and push the OBD II scan tool or hand held tester main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA COOLANT TEMP CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Same as actual engi...

Page 585: ... Connect the sensor wire harness terminals together c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA COOLANT TEMP CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Confirm good connection at sensor If OK re place engine coolant temperature sensor ...

Page 586: ...ted Before checking do a visual and contact pressure checks for the ECM connector See page IN 30 c Turn the ignition switch ON d When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST ALL DADA COOLANT TEMP CHECK Read the temperature value on the OBD II scan tool or hand held tester OK Temperature value 140 C 284 F or more OK Open in harness between terminals E2 a...

Page 587: ...re value on the OBD II scan tool or hand held tester OK Temperature value 40 C 40 F OK Replace engine coolant temperature sensor NG 5 Check for short in harness or ECM PREPARATION a Remove the ECM cover b Disconnect the E10 connector from the ECM HINT The engine coolant temperature sensor connector is discon nected c Turn the ignition switch ON d When using hand held tester enter the following men...

Page 588: ...When the temperature is high the resistance drops The variations in resistance are reflected in the voltage output from the sensor The ECM monitors the sensor voltage and uses this value to calculate the engine coolant temperature When the sen sor output voltage deviates from the normal operating range the ECM interprets this as a fault in the ECT sensor and sets a DTC Examples 1 Upon starting the...

Page 589: ...ithin 35 sec and stopped for 10 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Case1 When temperature is fixed between 35_C 95_F and 60_C 140_F Change of engine coolant temperature value Less than 3_C 5 4_F Case2 When temperature is fixed at 60_C 140_F or more Change of engine coolant temperature value 1_C 1 8_F or less COMPONENT OPERATING RANGE Standard Value Engine coolant tempe...

Page 590: ...rottle Pedal Position Sensor Switch A Circuit High Input DTC P0220 Throttle Pedal Position Sensor Switch B Circuit DTC P0222 Throttle Pedal Position Sensor Switch B Circuit Low Input DTC P0223 Throttle Pedal Position Sensor Switch B Circuit High Input DTC P2135 Throttle Pedal Position Sensor Switch A B Voltage Correction HINT This is repair procedure of throttle position sensor DIAK1 03 589 ...

Page 591: ...It detects the opening angle of the throttle valve This sensor is electronically controlled and uses Hall effect elements so that accurate control and reliability can be obtained The throttle position sensor has 2 sensor elements signal outputs VTA1 and VTA2 VTA1 is used to detect the throttle opening angle and VTA2 is used to detect malfunctions in VTA1 Voltage applied to VTA1 and VTA2 changes be...

Page 592: ... 2 x VTA1 x 1 8 V S Throttle position sensor S VTA2 circuit open S E2 circuit open S VC and VTA2 circuits are short circuited S ECM P0220 Detection conditions for DTCs P0222 and P0223 are not satis fied but condition a is satisfied a VTA2 x 0 5 V or VTA2 y 4 8 V and 0 2 x VTA1 x 1 8 V S Throttle position sensor S ECM P2135 Condition a continues for 0 5 sec or more or condition b continues for 0 4 ...

Page 593: ...by the force of the return spring The ECM then adjusts the engine output by controlling the fuel infection inter mittent fuel cut and ignition timing in accordance with the accelerator pedal opening angle to enable the vehicle to continue at a minimum speed If the accelerator pedal is depressed firmly and slowly the vehicle can be driven slowly If a pass condition is detected and then the ignition...

Page 594: ...V or more P0220 VTA2 voltage 0 5 V or less or 4 97 V or more P0222 VTA2 voltage 0 5 V or less P0223 Both of the following conditions are met A and B A VTA1 voltage 0 2 V or more and 1 8 V or less B VTA2 voltage 4 97 V or more P2135 Difference between VTA1 and VTA2 voltages 0 02 V or less Both of the following conditions are met A and B A VTA1 voltage 0 2 V or less B VTA2 voltage 0 5 V or less COMP...

Page 595: ...A19672 A19758 T1 Throttle Position Sensor 6 5 4 3 B W R B B L BR 28 VTA VC VTA2 E2 E10 E10 E10 E10 31 18 21 ECM VTA VC VTA2 E2 DI 396 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U WIRING DIAGRAM 594 ...

Page 596: ... ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL THROTTLE POS and THROTTLE POS 2 CHECK Read the voltage for the accelerator pedal position sensor data OK Result Throttle position expressed as percentage and voltage Trouble area Proceed to Accelerator pedal released Accelerator pedal depressed THROTTLE POS VTA1 THROTTLE POS 2 VTA2 THROTTLE POS VTA1 THROTTLE POS 2 VTA2 0 0 to 0...

Page 597: ...2 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON c Disconnect the throttle position sensor connector CHECK Measure the voltage between terminals VC and E2 of the ECM connector OK Voltage 4 5 to 5 5 V NG Replace ECM See page SF 78 OK 4 Replace throttle body See page SF 42 Go 596 ...

Page 598: ...ear the DTC See page DI 295 b Start the engine c Run the engine at idle for 15 seconds or more CHECK Read the DTC See page DI 295 RESULT Display DTC Output Proceed to P0120 P0122 P0123 P0220 P0222 P0223 and or P2135 are output again A No DTC output B OK System is OK NG Replace ECM See page SF 78 597 ...

Page 599: ...tion sensor See page IN 30 NG Repair or replace harness and connector OK 2 Check voltage between terminals VC and E2 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON c Disconnect the throttle position sensor connector CHECK Measure the voltage between terminals VC and E2 of the ECM connector OK Voltage 4 5 to 5 5 V NG Replace ECM See page SF 78 OK 3 Replace throttl...

Page 600: ...lear the DTC See page DI 295 b Start the engine c Run the engine at idle for 15 seconds or more CHECK Read the DTC See page DI 295 RESULT Display DTC Output Proceed to P0120 P0122 P0123 P0220 P0222 P0223 and or P2135 are output again A No DTC output B B System is OK A Replace ECM See page SF 78 599 ...

Page 601: ...deviates from the normal operating range the ECM interprets this as a malfunction of the throttle position sensor The ECM will turn on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle control valve returns to a predetermined opening angle approximately 16 by the force of the retur...

Page 602: ...Criteria Threshold TP sensor 1 TP sensor 2 x 0 8 corrected by learning value Less than 0 8 V or more than 1 6 V INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engin...

Page 603: ...es the signal voltage to vary The ECM monitors the ECT signal voltage after engine start up If after sufficient time has passed the sensor still reports that the engine is not warmed up enough for closed loop fuel control the ECM interprets this as a fault in the sensor or cooling system and sets a DTC Example The engine coolant temperature is 0_C 32_F at engine start After 5 min running time the ...

Page 604: ...re output simultaneously the engine coolant tem perature sensor circuit may be open or shorted Perform the troubleshooting of DTC P0115 P0117 or P0118 first S Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help determine if the vehicle was running or ...

Page 605: ...G Replace thermostat See page CO 9 OK 3 Check cooling system CHECK Check that there is defect cooling system which causes overcool such as abnormal radiator fan operation modified cooling system and so on NG Repair or replace cooling system OK Replace engine coolant temperature sensor 604 ...

Page 606: ...not reach 75 C 167 F despite sufficient warm up time has elapsed DTC No DTC Detecting Condition Trouble Area P0128 Conditions a b and c are met a Cold start b Engine is warmed up c THW 75 C 167 F S Thermostat S Cooling system S Engine coolant temperature sensor S ECM MONITOR DESCRIPTION The ECM estimates the coolant temperature based on starting temperature engine loads and engine speeds The ECM t...

Page 607: ...ry voltage 11 0 V Throttle position learning Completed Engine coolant temperature at engine start Intake air temperature at engine start 15_C 27_F 7_C 12 6_F Intake air temperature at engine start 10_C 14_F 35_C 95_F Engine coolant temperature at engine start 10_C 14_F 35_C 95_F Accumulated time that vehicle speed is 128 km h 80 mph or more 20 sec TYPICAL MALFUNCTION THRESHOLDS Detection Criteria ...

Page 608: ...scan tools TID 08 Thermostat TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 01 Multiply by 0 625 and subtract 40 C ECT sensor output when estimated ECT has reached to malfunction criterion Malfunction criteria for thermostat INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditio...

Page 609: ...ush the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P0128 A P0128 and other DTCs B HINT If any other codes besides P0128 is output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 335 A Re...

Page 610: ...gen concentration in the exhaust gas increases And the heated oxygen sensor informs the ECM of the LEAN condition low voltage i e less than 0 45 V When the air fuel ratio is richer than the stoichiometric air fuel ratio the oxygen will be vanished from the exhaust gas And the heated oxygen sensor informs the ECM of the RICH condition high voltage i e more than 0 45 V DTC No DTC Detection Condition...

Page 611: ... between 0 V and 1 V of the voltage output in response to the oxy gen concentration in the exhaust gas The sensor s output voltage varies suddenly in the vicinity of the stoi chiometric air fuel ratio Under a normal condition the output voltage from the heated oxygen sensor alternates between RICH and LEAN sides periodically When it is 0 4 V or less the air fuel ratio is judged as LEAN If the heat...

Page 612: ... for 28 sec or more 1 time or more Front oxygen sensor voltage is 0 4 V or more for 28 sec or more 1 time or more P2195 Front heated oxygen sensor voltage is 0 5 V or less for 28 sec 1 time or more P2196 Front heated oxygen sensor voltage is 0 4 V or more for 28 sec 1 time or more COMPONENT OPERATING RANGE Parameter Standard value Heated oxygen sensor voltage 0 to 1 V O2S TEST RESULT Refer to page...

Page 613: ...2A 1 2H 7 EA1 Y R 1 4 E11 23 6 E12 29 1 5 1 2 Y R B W B W B HT E1 OX1A 3 B EA1 8 EA1 2 1 B 4 1 W B B R H9 Heated Oxygen Sensor Bank 1 Sensor 2 2 B HT2 E1 OX1B 3 4 1 1 R R BR Engine Room J B BR 1 BR 2B 3 2F 26 2F 25 BR A A A A J1 J C FL MAIN BR A B W 5 IB 10 IB Battery EB E11 E11 E12 Y G 1 EA3 EA3 EA3 10 9 8 EC W B ED DI 414 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U WIRING DIAGRAM 612 ...

Page 614: ...followed detection of a malfunction will not occur If you do not have the hand held tester turn the ignition switch OFF after performing steps from c to f then perform steps from c to f again INSPECTION PROCEDURE HINT Hand held tester only Narrowing down the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sensor or other trouble areas can be distinguished Perform ACTIV...

Page 615: ...ar sensor The following of A F CONTROL procedure enables the technician to check and graph the voltage outputs of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button NOTICE If the vehicle is short of fuel the air fuel ratio becomes LEAN and...

Page 616: ...hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P0130 P2195 and or P2196 A P0130 P2195 and or P2196 and other DTCs B HINT If any other codes besides P0130 P2195 and or P2196 are output perform the troubleshooting for those DTCs fi...

Page 617: ...T ALL O2S B1S1 d Warm up the heated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor while idling OK Heated oxygen sensor output voltage Alternates repeatedly between less than 0 4 V and more than 0 5 V See the following table OK Go to step 9 NG 3 Check resistance of heated oxygen sensor heater PREPARATION Disco...

Page 618: ...9 2005 CELICA RM1131U 4 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Replace EFI relay OK 5 Check for open and short in harness and connector between ECM and heated oxygen sensor See page IN 30 NG Repair or repla...

Page 619: ...ressure See page SF 6 CHECK Check the fuel pressure high or low pressure NG Check and repair fuel pump pressure regulator fuel pipe line and filter See page SF 1 OK 8 Check injector injection See page SF 22 NG Replace injector OK Replace heated oxygen sensor bank 1 sensor 1 9 Perform confirmation driving pattern HINT Clear all DTCs prior to performing the confirmation driving pattern Go 618 ...

Page 620: ...OSTICS ENGINE 2ZZ GE DI 421 2005 CELICA RM1131U 10 Is there DTC P0130 P2195 or P2196 being output again NO Check for intermittent problems See page DI 295 YES Replace heated oxygen sensor bank 1 sensor 1 619 ...

Page 621: ...as The sensor detects oxygen levels in the exhaust gas and sends this signal to the ECM The inner surface of the sensor element is exposed to outside air The outer surface of the sensor element is exposed to exhaust gas The sensor element is made of platinum coated zirconia and includes an inte grated heating element The heated oxygen sensor has the characteristic whereby its output voltage change...

Page 622: ... per driving cycle Duration Within 60 sec MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITION Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 295 Slow slope condition There is a history that the following condi tions were met for 1 sec Condition 1 and 2 1 Vehicle speed 40 km h 25 mph 2 Engine RPM 900 rpm Idle ON ...

Page 623: ...quency monitor cruse If the 90 is out of the standard value the ECM interprets this as a malfunction TEST ID Description of TEST DATA Conversion Factor Unit 90 Remained value of that average of switching frequency is subtracted from average of switching frequen cy threshold Multiply by 0 04096 plus 5 2 sec WIRING DIAGRAM Refer to DTC P0130 on page DI 411 INSPECTION PROCEDURE HINT Hand held tester ...

Page 624: ... increase and decrease of injection volume 25 rich output More than 0 5 V 12 5 lean output Less than 0 4 V NOTICE There is a delay of few seconds in the sensor 1 front sensor output and there is about 20 seconds delay at maximum in the sensor 2 rear sensor The following of the A F CONTROL procedure enables the technician to check and graph the voltage out puts of both the heated oxygen sensors For...

Page 625: ... lean 1 Are there any other codes besides DTC P0133 being output PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed...

Page 626: ...ol main switch ON c When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL O2S B1S1 d Warm up the heated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output voltage Alternates between less than 0 35 V and more than 0 45 V and period ...

Page 627: ... resistance between the terminals HT and B of the heated oxygen sensor OK Resistance 11 to 16 Ω 20_C NG Replace heated oxygen sensor OK 4 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Replace EFI relay OK 626 ...

Page 628: ...heck for open and short in harness and connector between ECM and heated oxygen sensor Bank 1 Sensor 1 See page IN 30 NG Repair or replace harness or connector OK 6 Check air induction system CHECK Check the air induction system for vacuum leaks NG Repair or replace air induction system OK 7 Check fuel pressure See page SF 6 CHECK Check fuel pressure high or low pressure NG Check and repair fuel pu...

Page 629: ...Replace heated oxygen sensor bank 1 sensor 1 9 Perform confirmation driving pattern See page DI 411 HINT Clear all DTCs prior to performing the confirmation driving pattern Go 10 Is there DTC P0133 being output again NO Check for intermittent problems See page DI 295 YES Replace heated oxygen sensor bank 1 sensor 1 628 ...

Page 630: ...g the hand held tester or the OBD II scan tool If the output voltage of the heated oxygen sensor is always less than 0 1 V the sensor circuit may be open or shorted MONITOR DESCRIPTION The ECM uses the heated oxygen sensor to optimize the air fuel mixture in closed loop fuel control This control helps decrease exhaust emissions by providing the catalyst with a nearly stoichiometric mixture The sen...

Page 631: ...ge DI 411 INSPECTION PROCEDURE HINT Hand held tester only To determine the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sensor or other trouble areas can be distinguished a Perform ACTIVE TEST using the hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST which changes the injection volume to 12 5 or 25 1 Connect the hand held tester to the DLC3 on the v...

Page 632: ...and there is about 20 seconds delay at maximum in the sensor 2 rear sensor The following of the A F CONTROL procedure enables the technician to check and graph the voltage out puts of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button HINT...

Page 633: ...chart See page DI 335 A 2 Connect OBD II scan tool or hand held tester and read value for voltage output of heated oxygen sensor bank 1 sensor 1 PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c When using hand held tester enter the following menus DIAGNOSIS ENHANCED OB...

Page 634: ...gen sensor connector CHECK Measure resistance between the terminals HT and B of the heated oxygen sensor OK Resistance 11 to 16 Ω 20_C NG Replace heated oxygen sensor OK 5 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and ...

Page 635: ... 6 Check for open and short in harness and connector between ECM and heated oxygen sensor bank 1 sensor 1 See page IN 30 NG Repair or replace harness or connector OK 7 Check whether misfire is occurred or not by monitoring DTC and data list NG Perform troubleshooting for misfire See page DI 459 OK 8 Check air induction system See page SF 1 CHECK Check the air induction system for vacuum leaks NG R...

Page 636: ...fuel pipe line and filter See page SF 1 OK 10 Check injector injection See page SF 22 NG Replace injector OK 11 Check gas leakage on exhaust system NG Repair or replace exhaust gas leakage point OK Replace heated oxygen sensor bank 1 sensor 1 12 Perform confirmation of driving pattern See page DI 411 HINT Clear all DTCs prior to performing the confirmation pattern Go 635 ...

Page 637: ...05 CELICA RM1131U 13 Is there DTCs P0134 being output again YES Replace ECM See page SF 78 NO 14 Did vehicle run out of fuel in past NO Check for intermittent problems See page DI 295 YES DTCs P0134 are caused by running out of fuel 636 ...

Page 638: ...starts S HO2 sensor output voltage is 1 2 V or more for 10 seconds S HO2 sensor sensor 2 S Short in HO2 sensor sensor 2 circuit MONITOR DESCRIPTION The ECM monitors the HO2 sensor sensor 2 as follows S The HO2 sensor voltage does not remain RICH above 0 5 V or LEAN below 0 4 V while the vehicle is accelerated and decelerated for 4 to 8 minutes If the voltage remains either RICH or LEAN the ECM int...

Page 639: ...ion None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 P0136 Output voltage crack Vehicle speed 3 km h 1 875 mph Idle OFF Fuel cut OFF Time after fuel cut ON to OFF 15 sec Intake air amount per revolution 0 24 g rev P0136 Output voltage All of the following conditions are met A B C and D A Pass fail detection...

Page 640: ...voltage is 1 2 V or more 10 sec or more COMPONENT OPERATING RANGE Parameter Standard Value Heated oxygen sensor voltage 0 to 1 V O2S TEST RESULT MODE 05 DATA Refer to page DI 295 for detailed information Rear HO2S voltage monitor If the HO2S sensor voltage is out of the standard value the ECM interprets this as a malfunction TEST ID Description of TEST DATA Conversion Factor Unit 07 Minimum rear H...

Page 641: ...or more Multiplied by 0 2621 sec 87 Percentage of monitoring time when the HO2S voltage is 0 45 V or more Multiplied by 0 3906 WIRING DIAGRAM Refer to DTC P0130 on page DI 411 CONFIRMATION DRIVING PATTERN a Connect the hand held tester to the DLC3 b Switch the hand held tester from normal mode to check mode See page DI 295 c Start the engine and run at idle for 60 seconds or more d Drive the vehic...

Page 642: ...Almost no reaction Almost no reaction Almost no reaction DIAGNOSTICS ENGINE 2ZZ GE DI 443 2005 CELICA RM1131U INSPECTION PROCEDURE HINT Hand held tester only To determine the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sensor or other trouble areas can be distinguished a Perform ACTIVE TEST using the hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST ...

Page 643: ... determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides DTC P0136 or P0138 being output YES Go to relevant DTC chart See page DI 335 NO 2 Check output voltage of heated oxygen sensor PREPARATION a Connect the OBD II scan tool or the ...

Page 644: ...Check for open and short in harness and connectors between ECM and heated oxygen sensor See page IN 30 NG Repair or replace harness or connector OK 6 Perform confirmation of driving pattern GO 7 Is DTC P0136 or P0138 output again NO Check for intermittent problems See page DI 295 YES Replace heated oxygen sensor 643 ...

Page 645: ...dback is stable after warming up the engine fuel trim is considered to be in error on LEAN side 2 trip detection logic S Air induction system S Injector blockage S Mass air flow meter S Engine coolant temperature sensor S Fuel pressure S Gas leakage in exhaust system S Open or short in heated oxygen sensor bank 1 sensor 1 circuit S Heated oxygen sensor bank 1 sensor 1 S Heated oxygen sensor heater...

Page 646: ...mbination of smoothed short term fuel trim fuel feedback compensation value and smoothed long term fuel trim learning value of the air fuel ratio When the smoothed fuel trim learning val ue exceeds the DTC threshold the ECM interprets this as a fault in the fuel system and sets a DTC Example If the smoothed fuel trim learning value is more than 35 or less than 35 the ECM interprets this as a malfu...

Page 647: ... trim 35 or less varies with ECT WIRING DIAGRAM Refer to DTC P0130 on page DI 411 INSPECTION PROCEDURE HINT Hand held tester only To determine the trouble area is possible by performing A F CONTROL ACTIVE TEST heated oxygen sensor or other trouble areas can be distinguished a Perform ACTIVE TEST using the hand held tester A F CONTROL HINT A F CONTROL is the ACTIVE TEST which changes the injection ...

Page 648: ...and there is about 20 seconds delay at maximum in the sensor 2 rear sensor The following of the A F CONTROL procedure enables the technician to check and graph the voltage out puts of both the heated oxygen sensors For displaying the graph indication enter ACTIVE TEST A F CONTROL USER DATA then select O2S B1S1 and O2S B1S2 by pressing YES button and push ENTER button before pressing F4 button HINT...

Page 649: ...induction system See page SF 1 CHECK Check the air induction system for vacuum leaks NG Repair or replace air induction system OK 2 Check connection of PCV piping NG Repair or replace PCV piping OK 3 Check injector injection See page SF 22 NG Replace injector OK 648 ...

Page 650: ...1 Apply the battery voltage terminals B and E2G 2 Connect the positive tester probe to terminal VG and negative tester probe to terminal E2G 3 Blow air into the mass air flow meter and check that the voltage fluctuates b Inspect the resistance 1 Measure the resistance between the terminals of the intake air temperature sensor OK Tester Connection Temperature Specified Condition THA M1 4 E2 M1 5 20...

Page 651: ...to 0 326 kΩ NOTICE If you check the engine coolant temperature sensor in wa ter be careful not to allow water to go into the terminals Af ter checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor Compare the...

Page 652: ...U 7 Check fuel pressure See page SF 6 CHECK Check the fuel pressure high or low pressure NG Check and repair fuel pump fuel pipe line and filter See page SF 1 OK 8 Check gas leakage on exhaust system NG Repair or replace exhaust gas leakage point OK 651 ...

Page 653: ...TA LIST ALL O2S B1S1 d Warm up the heated oxygen sensor with the engine speed at 2 500 rpm for approximately 90 seconds CHECK Read the output voltage of the heated oxygen sensor during idling OK Heated oxygen sensor output voltage Alternates repeatedly between less than 0 4 V and more than 0 5 V See the following table OK Go to step 17 NG 10 Check resistance of heated oxygen sensor heater PREPARAT...

Page 654: ...LICA RM1131U 11 Check EFI relay PREPARATION Remove the EFI relay from the engine room J B CHECK Inspect the EFI relay OK Tester Connection Specified Condition 1 2 Continuity 3 5 No continuity Continuity Apply battery voltage to terminals 1 and 2 NG Replace EFI relay OK 12 Check for open and short in harness and connector between ECM and heated oxygen sensor bank 1 sensor 1 See page IN 30 NG Repair...

Page 655: ...page DI 295 L1 d Start the engine and let it idle until engine coolant temperature is 75 C 167 F or more L2 e Drive the vehicle at 19 mph 30 km h or more for 3 minutes or more L3 f Let the engine idle for approx 2 minutes L4 g Perform steps e and g at least 3 times HINT If a malfunction exists the MIL will be illuminated during step f NOTICE If the conditions in this test are not strictly followed...

Page 656: ... by fuel shortage 17 Perform confirmation driving pattern HINT Clear all DTCs prior to performing the confirmation driving pattern Refer to step 14 Go 18 Is there DTC P0171 or P0172 being output again NO Go to step 22 YES 19 Replace heated oxygen sensor Go 20 Perform confirmation driving pattern HINT Clear all DTCs prior to performing the confirmation driving pattern Refer to step 14 Go 655 ...

Page 657: ...r P0172 being output again YES Replace ECM See page SF 78 and perform confirmation driving pattern Refer to step 14 NO 22 Confirm if vehicle has run out of fuel in the past NO Check for intermittent problems See page DI 295 YES DTC P0171 or P0172 is caused by fuel short age 656 ...

Page 658: ...position sensor and the crankshaft position sensor The camshaft position sensor is used to identify misfiring cylinders and crankshaft position sensor is used to measure variations in the crankshaft rotation speed A misfire is counted when crankshaft rotation speed variations exceed threshold values The ECM illuminates the MIL if the misfiring rate exceeds a threshold value which could cause emiss...

Page 659: ...ITOR DESCRIPTION The ECM illuminates the MIL 2 trip detection logic if The ECM will illuminate the MIL when the percentage of misfire exceeds the specified limit per 1 000 engine revolutions One occurrence of excessive misfire during engine start will illuminate the MIL Four occur rences are required to illuminate the MIL 1 000 revolutions after engine start The ECM blinks the MIL the MIL blinks i...

Page 660: ...L blinking Catalyst deteriorating misfire Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 Battery voltage 8 V Throttle position learning Completed VVT sytem Not operated by scan tool Engine RPM 400 rpm 7 800 rpm All of the following conditions are met Condition 1 and 2 1 Engine coolan...

Page 661: ...C 9 IK 11 5 6 AM2 IG2 IK 4 IC 6 I10 I6 I7 I8 I9 L E10 E10 E10 B O J6 J C C C DI 462 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Monitor period of emission related misfire Misfire rate 1 3 or more Monitor period of catalyst damage misfire Number of misfire per 200 revolutions 101 or more varies with engine RPM and intake air amount WIRIN...

Page 662: ...roubleshooting freeze frame data can help determine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred S If the misfire does not occur when the vehicle is brought to the workshop the misfire can be confirmed by reproducing the condition of the freeze frame data Also after fi...

Page 663: ...S CHECK Read the DTCs RESULT Display DTC output Proceed to P0300 P0301 P0302 P0303 and or P0304 A P0300 P0301 P0302 P0303 and or P0304 and other DTCs B HINT If any other codes besides P0300 P0301 P0302 P0303 and or P0304 are output perform the trouble shooting for those DTCs first B Go to relevant DTC chart See page DI 335 A 2 Check harness connector and vacuum hose in engine room CHECK a Check th...

Page 664: ...or the OBD II scan tool main switch ON c Start the engine d When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL CYL 1 to CYL 4 CHECK Read the number of misfire cylinder on the hand held tester or the OBD II scan tool HINT When a misfire is not reproduced be sure to branch below based on the stored DTC RESULT High Misfire Rate Cylinder Proceed to 1 or 2 cyli...

Page 665: ...t wet with gasoline or oil c Electrode gap 1 0 to 1 3 mm 0 039 to 0 051 in NOTICE If adjusting the gap of a new spark plug bend only the base ground electrode Do not touch the tip Never attempt to adjust the gap of a used plug PREPARATION a Install the spark plug to the ignition coil assembly b Disconnect the injector connector c Ground spark plug CHECK Check if spark occurs while engine is being ...

Page 666: ... b Disconnect the injector connector c Ground the spark plug CHECK Check if spark occurs while the engine is being cranked CAUTION Always disconnect each injector connector NOTICE Do not crank the engine for more than 2 seconds OK Spark jumps across electrode gap OK Replace spark plug NG 7 Check for open and short in harness and connector between ignition coil and ECM See page IN 30 OK Replace ign...

Page 667: ...f the ECM con nector and body ground OK Voltage 9 to 14 V OK Go to step 11 NG 9 Check resistance of injector of misfiring cylinder See page SF 18 NG Replace injector OK 10 Check for open and short in harness and connector between ignition switch and injector injector and ECM of misfiring cylinder See page IN 30 NG Repair or replace harness or connector OK 11 Check injector injection and volume of ...

Page 668: ...ring cylinder See page EM 4 NG Adjust valve clearance OK 14 Check result of step 4 switch step by number of misfire cylinder High misfire rate cylinder Proceed to 1 or 2 cylinders A more than 3 cylinders B B Check for intermittent problems See page DI 295 A 15 Check valve timing Check for loose or a jumped tooth of the timing chain See page EM 26 NG Adjust valve timing OK 667 ...

Page 669: ...ester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL INTAKE AIR 2 Read its value displayed on the hand held tester or the OBD II scan tool OK Equivalent to ambient temperature b Check the air flow rate 1 When using hand held tester enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL MAF 2 Read its value displayed on the hand held tester or the OBD II scan tool OK Con...

Page 670: ...sensor in wa ter be careful not to allow water to go into the terminals Af ter checking dry the sensor HINT Alternate procedure Connect an ohmmeter to the installed en gine coolant temperature sensor and read the resistance Use an infrared thermometer to measure the engine temperature in the immediate vicinity of the sensor Compare these values to the resistance temperature graph Change the engine...

Page 671: ...Knock sensor under torqued or loose S ECM P0328 Output voltage of the knock sensor is 4 5 V or more S Open in knock sensor circuit S Knock sensor under torqued or loose S ECM HINT If the ECM detects the DTC P0327 and P0328 it enters the fail safe mode in which the corrective retarded angle value is set to the maximum value Reference Inspection by using the oscilloscope After warning up run the eng...

Page 672: ...sor Engine coolant temperature sensor Mass air flow meter Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 Battery voltage 10 5 V Time after engine start 5 sec Ignition switch ON Starter OFF TYPICAL MALFUNCTION TH...

Page 673: ...reeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 672 ...

Page 674: ...GNOSIS ENHANCED OBD II DTC INFO CURRENT CODES d Clear the DTCs e Warm up the engine f Run the engine at 3 000 rpm for 10 seconds or more CHECK Read the DTCs RESULT Display DTC output Proceed to P0327 and or P0328 A No output B B Check for intermittent problems See page DI 295 A 2 Check for open and short in harness and connector between ECM and knock sensor PREPARATION Disconnect the E11 ECM conne...

Page 675: ... the voltage between the terminals of the ECM connec tor OK Voltage 4 5 to 5 5 V NG Replace ECM See page SF 78 OK Check for intermittent problems See page DI 295 NOTICE Fault may be intermittent Check wire harness and connectors carefully 4 Check knock sensor PREPARATION Remove the knock sensor CHECK Measure the resistance between the terminals OK Resistance 120 to 280 kΩ at 20 C 68 F NG Replace k...

Page 676: ...n this sensor communicates the rotation of the NE signal plate as a pulse signal to the ECM Based on the signal the ECM controls fuel injection time and ignition timing DTC No DTC Detection Condition Trouble Area P0335 No crankshaft position sensor signal to ECM during cranking 2 trip detection logic S Open or short in crankshaft position sensor circuit S Crankshaft position sensor S Signal plate ...

Page 677: ...nts Engine speed sensor Frequency of operation Continuous Duration Case 1 4 7 sec Case 2 0 016 sec MIL operation 2 driving cycles Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 Case 1 Starter ON Minimum battery voltage while starter is ON 11 V Case 2 Engine speed 600 rpm Starter OFF ...

Page 678: ...air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred S READ VALUE OF HAND HELD TESTER OR OBD II SCAN TOOL a Connect the hand held tester or the OBD II scan tool to the DLC3 b Start the engine and push the hand held tester or the OBD II scan tool main switch ON c Select the menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL ENGINE SPD S The engine speed can be c...

Page 679: ...cified Condition 1 2 1 630 to 2 740 Ω at cold 2 065 to 3 225 Ω at hot NOTICE Cold and Hot shown above mean the temperature of the coils themselves Cold is from 10_C 14_F to 50_C 122_F and Hot is from 50_C 122_F to 100_C 212_F NG Replace crankshaft position sensor OK 2 Check for open and short in harness and connector between ECM and crankshaft position sensor See page IN 30 NG Repair or replace ha...

Page 680: ... GE DI 481 2005 CELICA RM1131U 4 Check teeth of signal plate PREPARATION Remove the crankshaft angle sensor plate See page EM 19 CHECK Check the teeth of sensor plate NG Replace signal plate OK Replace ECM See page SF 78 679 ...

Page 681: ... every engine revolution The ECM detects the crankshaft angle and the en gine revolution based on the NE signal and the cylinder and angle of VVT based on the combination of the G and NE signal DTC No DTC Detection Condition Trouble Area P0340 S No camshaft position sensor signal to ECM during cranking 2 trip detection logic S No camshaft position sensor signal to ECM at engine speed 600 rpm or mo...

Page 682: ...40 case 1 no signal 2 driving cycles P0340 case 2 mis aligned P0341 Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 P0340 Case 1 No signal Starter ON Minimum battery voltage while starter is ON 11 V P0340 Case 2 Mis aligned Engine speed 600 rpm Starter OFF P0341 Starter Afte...

Page 683: ...ed if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check resistance of camshaft position sensor See page IG 1 CHECK Measure the resistance between the terminals of camshaft position sensor connector OK Tester Connection Specified Condition 1 2 835 to 1 400 Ω at cold 1 060 to 1 645 Ω at hot NOTICE Cold and H...

Page 684: ...5 2005 CELICA RM1131U 3 Inspect sensor installation CHECK Check the camshaft position sensor installation NG Tighten sensor OK 4 Check teeth of camshaft timing pulley NG Replace camshaft timing pulley OK Replace ECM See page SF 78 683 ...

Page 685: ...iability of the ignition system by eliminating the distributor The DIS is a 1 cylinder ignition system which ignites one cylinder with one ignition coil In the 1 cylinder ignition system the one spark plug is connected to the end of the secondary winding High voltage generated in the secondary winding is applied directly to the spark plug The spark of the spark plug passes from the center electrod...

Page 686: ...on Coil with Igniter B16829 IGT signal waveform 2 V Division IGT GND IGF GND 20 m sec Division DIAGNOSTICS ENGINE 2ZZ GE DI 487 2005 CELICA RM1131U DTC No DTC Detecting Condition Trouble Area P0351 P0352 P0353 P0354 No IGF signal to ECM while engine is running S Open or short in IGF and IGT1 IGT4 circuit from ignition coil with igniter to ECM S No 1 to No 4 ignition coil with igniter S Ignition sy...

Page 687: ... the IGT it interprets this as a fault in the igniter and sets a DTC MONITOR STRATEGY Related DTCs P0351 No 1 ignition coil with igniter circuit malfunction P0352 No 2 ignition coil with igniter circuit malfunction P0353 No 3 ignition coil with igniter circuit malfunction P0354 No 4 ignition coil with igniter circuit malfunction Required sensors components Igniter Frequency of operation Continuous...

Page 688: ...nditions are met a and b a Engine speed 500 rpm b Battery voltage 6 V B Following conditions are met a and b a Engine speed 500 rpm b Battery voltage 10 V TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Ignition signal fail count More than 2 times Condition when ignition signal fail count works IGF should have returned despite sending IGT COMPONENT OPERATING RANGE Standard Value Confir...

Page 689: ...n Coil with Igniter No 2 4 2 1 B Y B W B 3 Ignition Coil with Igniter No 3 4 2 1 G R B Y B W B 3 Ignition Coil with Igniter No 4 4 2 1 R Y B Y B W B B 1 2 C C W B W B EC 3 2 5 1 14 2F Instrument Panel J B I10 Ignition Switch IG2 IG2 AM2 16 2F 1 2A 2H 7 2G 4 W B W B EB IC 6 IK 4 B O 6 5 AM2 B R B R B R IK 11 IC 9 10 11 EM I2 I3 I4 I5 N1 Noise Filter ECM E10 E10 E10 E10 B O W B DI 490 DIAGNOSTICS EN...

Page 690: ...n a malfunction occurred 1 Check spark plug and spark of misfiring cylinder See page IG 1 NG Go to step 4 OK 2 Check for open and short in harness and connector in IGF signal circuit between ECM and ignition coil with igniter See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminals IGF of ECM connector and body ground PREPARATION a Remove the ECM cover b Discon...

Page 691: ... of ECM connector and body ground PREPARATION Remove the ECM cover CHECK Measure voltage between terminals IGT1 to 4 of the ECM con nector and body ground when engine is cranked OK Voltage More than 0 1 V and less than 4 5 V NG Replace ECM See page SF 78 OK 6 Check voltage between terminals IGT1 to 4 of ECM connector and body ground PREPARATION Disconnect the ignition coil with igniter connector C...

Page 692: ...ge between terminal 1 of the ignition coil with igniter connector and body ground when the ignition switch is turned to ON and START position OK Voltage 9 to 14 V NG Repair ignition coil with igniter power source circuit OK 8 Check for open and short in harness and connector between ignition switch and ignition coil with igniter See page IN 30 NG Repair or replace harness or connector OK Replace i...

Page 693: ...gen Sensor sensor 1 the second is mounted downstream Rear Oxy gen Sensor sensor 2 The catalyst efficiency monitor compares the sensor 1 and sensor 2 signals in order to calculate TWC ability to store the oxygen During normal operation the TWC stores and releases oxygen as needed This results in low oxygen varia tions in the post TWC exhaust stream as shown below DTC Detecting Condition Trouble Are...

Page 694: ...ENABLING CONDITIONS Item Specification Minimum Maximum These DTCs are not present See page DI 295 Accumulated time that all of the following conditions are met 30 sec Battery voltage 11 V Intake air temperature 10_C 14_F Idle status OFF Intake air amount 8 g sec 25 g sec Engine RPM 4 500 rpm Engine coolant temperature 75 C 167 F Catalyst temperature M T 500_C 932_F 900_C 1652_F Catalyst temperatur...

Page 695: ...it Conversion Description of Test Data Description of Test Limit 0 01 Multiplied by 0 0078 no dimension Catalyst deterioration level Malfunction criteria for catalyst deterioration CONFIRMATION DRIVING PATTERN a Clear the DTC b Warm up the engine until the engine coolant temperature reaches 75 C 167 F c Drive the vehicle at 40 to 55 mph 64 to 88 km h for at least 3 minutes d Drive the vehicle at 3...

Page 696: ...e if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides DTC P0420 being output If a DTC other than P0420 is set troubleshoot for the DTC first RESULT DTC Proceed to P0420 A P0420 and others B B Go to relevant DTC chart See page DI 335 A 2 Che...

Page 697: ...ltage Extremely rich or lean fuel trim etc Almost no reaction Almost no reaction Almost no reaction Almost no reaction Catalysts Go to Heated oxygen sensor Bank 1 Sensor 1 Heated oxygen sensor Bank 1 Sensor 2 DI 498 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U 3 Perform A F CONTROL active test a Connect the hand held tester to the DLC3 b Run the engine at 2500 rpm for 90 seconds c Allow the engin...

Page 698: ...005 CELICA RM1131U B Replace heated oxygen sensor bank 1 sensor 1 See page EM 117 C Replace heated oxygen sensor bank 1 sensor 2 See page EM 117 D Check fuel trim See page DI 445 A Replace front exhaust pipe catalyst See page EM 117 697 ...

Page 699: ...DI 500 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U MEMO 698 ...

Page 700: ...ION The vapor pressure sensor canister closed valve CCV and pressure switching valve are used to detect abnormalities in the evaporative emission control system The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal DTCs P0441 and P0446 are recorded by the ECM when evaporative emissions leak from the components within th...

Page 701: ...tected in the evaporative emission EVAP VSV the canister closed valve CCV and the bypass valve the ECM will illuminate the MIL and set a DTC This portion of the EVAP diagnosis checks the following EVAP system functions a CCV stuck closed The ECM checks for a CCV stuck closed malfunction by commanding the CCV to open after an EVAP leak test If the fuel tank pressure does not rise no vacuum generate...

Page 702: ...essure when commanding the pressure switching valve to be checked after the EVAP leak test A high negative pressure vacuum does not occur in the sys tem when commanding the EVAP VSV to open with the CCV closed HINT Typical DTC output of each trouble part is shown in the table below Trouble part Typical DTC output 1 Small Leak P0442 and or P0456 2 Medium Leak ex Vacuum hose loose P0442 Large Leak e...

Page 703: ...han 0 9 kPa 7 mmHg 0 27 in Hg B Following conditions are met for 14 sec a and b A Difference between minimum fuel tank pressure before the leak check and fuel tank pressure at 14 sec after the leak check 0 46 kPa or more 3 5 mmHg 0 14 in Hg b Fuel tank pressure 14 sec after the leak check Less than 3 7 kPa 28 mmHg 1 1 in Hg P0446 Detection Criteria Threshold Case 1 CCV stuck closed Fuel tank press...

Page 704: ... Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools TID 02 EVAP system Vacuum monitor TLT CID Unit Conversion Description of Test Data Description of Test Limit 1 01 Multiplied by 0 0916 mmHg Test value of EVAP VSV Determined by fuel tank pressure change during vacuum introduction Malfunction criteria for EVAP VSV 1 02 Multiplied by 0 0458 subtract 2 93 mmHg...

Page 705: ... P0446 CCV or pressure switching valve P0451 P0452 or P0453 See page DI 545 is output with DTC P0442 or P0456 See page DI 524 first troubleshoot DTC P0441 P0446 P0451 P0452 or P0453 If no malfunction is detected troubleshoot DTC P0442 or P0456 next S Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detec...

Page 706: ... a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 705 ...

Page 707: ... right or left button CHECK When the EVAP VSV is operated by the hand held tester check whether the disconnected hose applies suction to your finger OK VSV is ON Disconnected hose applies suction to your finger VSV is OFF Disconnected hose applies no suction to your finger OK Go to step 9 NG 6 Check vacuum hose between intake manifold and EVAP VSV and EVAP VSV and charcoal canister CHECK a Check t...

Page 708: ...ation of EVAP VSV See page SF 61 NG Replace EVAP VSV OK 8 Check for open and short in harness and connector between EFI main relay Marking EFI and EVAP VSV and EVAP VSV and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 707 ...

Page 709: ...the ACTIVE TEST and operate CAN CTRL VSV Press the right or left button CHECK Check the CCV operation when it is operated by the hand held tester OK CCV is ON Air does not flow from port E to port F CCV is OFF Air from port E flows out through port F OK Go to step 13 NG 10 Check vacuum hose between CCV and charcoal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacu...

Page 710: ... the hand held tes ter main switch ON b Select the ENHANCED OBD II ACTIVE TEST mode on the hand held tester c Select the menu TANK BYPASS VSV ALL in the AC TIVE TEST and operate TANK BYPASS VSV Press the right or left button CHECK Check the pressure switching valve operation when it is oper ated by the hand held tester OK Pressure switching valve is ON Air from port E flows out through port F Pres...

Page 711: ... there are signs of any accident near fuel tank CHECK Check for cracks deformation and loose connection of the fol lowing parts S Fuel tank S Fuel tank filler pipe S Hoses and tubes around fuel tank NG Repair or replace evaporative emission leak point OK 17 Check vacuum hoses between vapor pressure sensor and fuel tank and char coal canister and pressure switching valve CHECK a Check that the vacu...

Page 712: ...el evap pipe and fuel tube under the floor fuel tube under the floor and charcoal canister b Check the hose and tube for cracks holes and damages NG Repair or replace hose and tube OK 19 Check voltage between terminals VC and E2 of ECM connector CHECK a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals VC and E2 of the ECM connector OK Voltage 4 5 to 5 ...

Page 713: ... vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor NOTICE The vacuum applied to the vapor pressure sensor must be less than 66 7 kPa 500 mmHg 19 7 in Hg OK Condition 1 Voltage 2 9 to 3 7 V Condition 2 Voltage 0 5 V or less OK Go to step 22 NG 21 Check for open and short in harness and connector between vapor p...

Page 714: ... ENGINE 2ZZ GE DI 515 2005 CELICA RM1131U 23 Check fuel tank NG Replace fuel tank OK 24 Check charcoal canister for cracks holes and damages NG Repair or replace charcoal canister OK Replace ECM See page SF 78 713 ...

Page 715: ... Replace with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 714 ...

Page 716: ...por pressure sensor and fuel tank charcoal canister and pressure switching valve and pressure switching valve and char coal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks holes and damages NG Repair or connect VSV or sensor connector OK 7 Check hose and tube between fuel tank and charcoal...

Page 717: ...d disconnection c Check the vacuum hose for cracks holes damages and blockage NG Repair or replace vacuum hose OK 9 Check connector for EVAP VSV connector for CCV connector for pressure switching valve and vapor pressure sensor connector for looseness and discon nection NG Repair or connect VSV or sensor connector OK 10 Check charcoal canister for cracks holes and damages NG Check and replace char...

Page 718: ...tween terminals PTNK and E2 of ECM connectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connector under following condition 1 and 2 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor N...

Page 719: ...See page SF 78 14 Check EVAP VSV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect the terminal EVP of the ECM connector and body ground ON 2 Disconnect the terminal EVP of the ECM connector and body ground OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK Go to step 17 NG 15 Che...

Page 720: ...nnector OK Replace ECM See page SF 78 17 Check CCV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the CCV function 1 Connect the terminal CCV of the ECM connector and body ground ON 2 Disconnect the terminal CCV of the ECM connector and body ground OFF OK 1 CCV is ON Air does not flow from port E to port F 2 CCV is OFF Air from port E flows out through port F OK Go to...

Page 721: ...PARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the pressure switching valve function 1 Connect the terminal TBP of the ECM connector and body ground ON 2 Disconnect the terminal TBP of the ECM connector and body ground OFF OK 1 Pressure switching vavle is ON Air from port E flows out through port F 2 Pressure switching valve is OFF Air does not from flow port E to port F...

Page 722: ... EFI and pressure switching valve and pressure switching valve and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 23 Check fuel tank inlet valve NG Replace fuel tank inlet valve OK 24 Check fuel tank NG Replace fuel tank OK It is likely that vehicle user did not properly close fuel tank cap 721 ...

Page 723: ... Leak Detected Very Small Leak CIRCUIT DESCRIPTION The vapor pressure sensor canister closed valve CCV and pressure switching valve are used to detect abnormalities in the evaporative emission control system The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal DTC P0442 or P0456 is recorded by the ECM when evaporative ...

Page 724: ...it for EVAP VSV S EVAP VSV S Open or short in circuit for CCV S CCV S Open or short in circuit for pressure switching valve S Pressure switching valve S Fuel tank is cracked or damaged S Charcoal canister is cracked or damaged S Fuel tank over fill check valve is cracked or damaged S ECM P0456 The pressure in the EVAP system slightly increases while the ECM performs a leak check very small leak 2 ...

Page 725: ... disables the diagnosis c Opens the EVAP VSV to introduce a negative pressure vacuum from the intake manifold into the fuel tank d Closes the EVAP VSV to seal the fuel tank for storing the negative pressure e Monitors the negative pressure in the fuel tank for 1 Rapid decrease i e a large leak 0 040 inch or more 2 Decrease greater than the normal value If the ECM detects either of the above condit...

Page 726: ...1 Purge duty cycle 15 or more when intake air amount is 8 g sec or more 2 Purge concentration for 30 sec 5 or more when vehicle speed is less than 10 km h 6 2 mph Fuel slosh No sloshing i e fairly smooth road Time after engine start 50 min Fuel tank pressure change before vacuum introduction Minimum change Fuel level 90 0 040 inch leak Not detected CCV malfunction bypass VSV malfunc tion Not detec...

Page 727: ...result and test values after performing the monitor drive pattern see page DI 326 S TID Test Identification Data is assigned to each emissions related component S TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit S CID Component Identification...

Page 728: ...place with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 727 ...

Page 729: ... right or left button CHECK When the EVAP VSV is operated by the hand held tester check whether the disconnected hose applies suction to your finger OK VSV is ON Disconnected hose applies suction to your finger VSV is OFF Disconnected hose applies no suction to your finger OK Go to step 9 NG 6 Check vacuum hose between intake manifold and EVAP VSV and EVAP VSV and charcoal canister CHECK a Check t...

Page 730: ...place ECM See page SF 78 9 Check CCV PREPARATION a Disconnect the vacuum hose for the CCV from the char coal canister b Turn the ignition switch ON and push the hand held tes ter main switch ON c Select the ENHANCED OBD II ACTIVE TEST mode on the hand held tester d Select the menu CAN CTRL VSV ALL in the ACTIVE TEST and operate CAN CTRL VSV Press the right or left button CHECK Check the CCV operat...

Page 731: ...e for looseness and disconnection c Check the vacuum hose for cracks holes damages and blockage NG Repair or replace vacuum hose OK 11 Check operation of CCV See page SF 63 NG Replace CCV OK 12 Check for open and short in harness and connector between EFI main relay Marking EFI and CCV and CCV and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 730 ...

Page 732: ...tton CHECK Check the pressure switching valve operation when it is oper ated by the hand held tester OK Pressure switching valve is ON Air from port E flows out through port F Pressure switching valve is OFF Air does not flow from port E to port F OK Go to step 16 NG 14 Check operation of pressure switching valve See page SF 65 NG Replace pressure switching valve OK 15 Check for open and short in ...

Page 733: ... Check vacuum hoses between vapor pressure sensor and fuel tank and char coal canister and pressure switching valve CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks holes and damages NG Repair or replace vacuum hose OK 18 Check hose and tube between fuel tank and charcoal canister CHECK a Check for ...

Page 734: ...tween terminals PTNK and E2 of ECM connectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connector under following condition 1 and 2 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor N...

Page 735: ...r and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 22 Check fuel tank inlet valve NG Replace fuel tank inlet valve OK 23 Check fuel tank NG Replace fuel tank OK 24 Check charcoal canister for cracks holes and damages NG Repair or replace charcoal canister OK Replace ECM See page SF 78 734 ...

Page 736: ... Replace with a cap that meets OEM specifica tions OK 2 Check that fuel tank cap is correctly installed NG Correctly install fuel tank cap OK 3 Check fuel tank cap See page EC 6 NG Replace fuel tank cap OK 4 Check filler neck for damage PREPARATION Remove the fuel tank cap CHECK Visually inspect the filler neck for damage NG Replace filler pipe OK 735 ...

Page 737: ...een vapor pressure sensor and fuel tank charcoal canister and pressure switching valve and pressure switching valve and char coal canister CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks holes and damages NG Repair or replace vacuum hose OK 7 Check hose and tube between fuel tank and charcoal canis...

Page 738: ...d disconnection c Check the vacuum hose for cracks holes damage and blockages NG Repair or replace vacuum hose OK 9 Check connector for EVAP VSV connector for CCV connector for pressure switching valve and vapor pressure sensor connector for looseness and discon nection NG Repair or connect VSV or sensor connector OK 10 Check charcoal canister for cracks holes and damages NG Check and replace char...

Page 739: ...tween terminals PTNK and E2 of ECM connectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connector under following condition 1 and 2 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor N...

Page 740: ...See page SF 78 14 Check EVAP VSV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the VSV function 1 Connect the terminal EVP of the ECM connector and body ground ON 2 Disconnect the terminal EVP of the ECM connector and body ground OFF OK 1 VSV is ON Air from port E flows out through port F 2 VSV is OFF Air does not flow from port E to port F OK Go to step 17 NG 15 Che...

Page 741: ...pair or replace harness or connector OK Replace ECM See page SF 78 17 Check CCV PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the CCV function 1 Connect the terminal CCV of the ECM connector and body ground ON 2 Disconnect the terminal CCV of the ECM connector and body ground OFF OK 1 CCV is ON Air does not flow from port E to port F 2 CCV is OFF Air from port E flow...

Page 742: ...or connector OK Replace ECM See page SF 78 20 Check pressure switching valve PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Check the pressure switching valve function 1 Connect the terminal TBP of the ECM connector and body ground ON 2 Disconnect the terminal TBP of the ECM connector and body ground OFF OK 1 Pressure switching vavle is ON Air from port E flows out through ...

Page 743: ...rness and connector between EFI main relay Marking EFI and pressure switching valve and pressure switching valve and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 23 Check fuel tank inlet valve NG Replace fuel tank inlet valve OK 24 Check fuel tank NG Replace fuel tank OK It is likely that vehicle user did not properly close fuel tank cap 742 ...

Page 744: ...cle is stationary and there should be little variation in the tank pressure If the indicated pressure value exceeds specified limits the ECM will illuminate the MIL and a DTC will be set The ECM checks for a stuck sensor by monitoring the fuel tank pressure for an extended time period If the indicated pressure value does not change over this period the ECM will conclude that the fuel tank pres sur...

Page 745: ...rouble Area P0451 Vapor pressure sensor output extremely changes under condi tions of a and b 2 trip detection logic a Vehicle speed 0 km h 0mph Engine speed Idling and pressure switching valve is OFF b Vapor pressure sensor value y opening pressure valve of charcoal canister S Open or short in vapor pressure sensor circuit S Vapor pressure sensor S ECM P0452 Open in vapor pressure sensor circuit ...

Page 746: ...re sensor Noise monitor 10sec Fuel tank pressure sensor Stuck monitor 20 min MIL operation 2 driving cycles Sequence of operation None P0452 and P0453 Related DTCs P0452 Evaporative emission control system pressure sensor switch low input P0453 Evaporative emission control system pressure sensor switch high input Required sensors components Main sensors components Vapor pressure sensor Related sen...

Page 747: ... 20_F Engine coolant temperature at engine start 4 4_C 40_F 35_C 95_F Intake air temperature at engine start 4 4_C 40_F 35_C 95_F Time after vehicle stop and idling 5 sec 15 sec Bypass VSV Closed Fuel tank pressure sensor Stuck monitor Altitude 2 400 m 7 872 ft Battery voltage 11 V Throttle position learning Completed Vapor pressure sensor No malfunction Fuel tank pressure sensor malfunction P0452...

Page 748: ... Fuel tank pressure 1 999 kPa 15 mmHg or more WIRING DIAGRAM Refer to DTC P0441 on page DI 501 INSPECTION PROCEDURE HINT S If different DTCs related to different systems that have terminal E2 as the ground terminal are output simultaneously terminal E2 may be open S If DTC P0441 Purge Flow P0446 CCV P0451 P0452 or P0453 Evaporative Pressure Sensor is output with DTC P0442 or P0456 troubleshoot DTC...

Page 749: ...onnectors PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminals PTNK and E2 of the ECM connectors 1 Disconnect the vacuum hose from the vapor pres sure sensor 2 Using the MITYVAC Hand Held Vacuum Pump apply a vacuum of 4 0 kPa 30 mmHg 1 18 in Hg to the vapor pressure sensor 3 Check the vapor pressure sensor output waveform using a hand held te...

Page 750: ...E 2ZZ GE DI 551 2005 CELICA RM1131U 3 Check for open and short in harness and connector between vapor pressure sen sor and ECM See page IN 30 NG Repair or replace harness or connector OK Replace vapor pressure sensor 749 ...

Page 751: ...combination meter it is then transmitted to the ECM The ECM determines the vehicle speed based on the frequency of these pluse signals DTC No DTC Detecting Condition Trouble Area P0500 P0503 During vehicle is being driven no vehicle speed sensor signal to ECM 2 trip detection logic S Combination meter S Open or short in vehicle speed sensor circuit S Vehicle speed sensor S ECM MONITOR DESCRIPTION ...

Page 752: ...C is not present See page DI 295 Case 1 MT Engine coolant temperature 70 C 158 F Engine speed 2 000 rpm 4 000 rpm Intake air amount per engine revolution 0 34 g rev Fuel cut at high engine speed Not executing Case 2 AT Engine Running Either of the following conditions are met A or B A All of the following conditions are met a and b a Time after park neutral position switch turns from ON to OFF 2 s...

Page 753: ...ubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check operation of speedometer CHECK Drive the vehicle and check if the operation of the speedmeter in the combination meter is normal HINT The vehicle speed sensor is ope...

Page 754: ...t lever to neutral c Jack up one of the front wheels d Turn the ignition switch ON CHECK Measure voltage between terminal SPD of ECM connector and body ground when the wheel is turned slowly OK Voltage is generated intermittently HINT The output voltage should fluctuate up and down similarly to the diagram on the left when the wheel is turned slowly NG Repair or replace harness or connector OK Rep...

Page 755: ...s STP and ST1 The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch HINT Normal condition is as shown in the table Signal Brake pedal released In transition Brake pedal depressed STP OFF ON ON ST1 ON ON OFF DTC No DTC Detection Condition Trouble Area P0504 Conditions a b and c continue for 0 5 seconds or more a Ignition switch ON b Brake pedal released c STP signal i...

Page 756: ...4 J C J12 J C C J12 C J13 A J13 A G W G W 3 2 5 W B 2 5 2 1 W B 2 W B A G W G W Instrument Panel J B Instrument Panel J B Engine Room J B H10 High Mounted Stop light R6 Stop Light LH AM2 16 2F B R 9 IC 11 IK B R AM2 IG2 5 B O 6 IE3 4 C C 3 B O R Y 9 R Y 12 E8 ST1 BA1 BJ BL BA1 G W Instrument Panel J B DIAGNOSTICS ENGINE 2ZZ GE DI 557 2005 CELICA RM1131U WIRING DIAGRAM 755 ...

Page 757: ...was lean or rich as well as other data from the time when a malfunction occurred Hand held tester 1 Check operation of stop light PREPARATION Check if the stop lights come on and go off normally when the brake pedal is operated and released NG Check and repair stop light circuit See page BE 37 OK 2 Check STOP fuse PREPARATION Remove the STOP fuse from the instrument panel J B CHECK Check the conti...

Page 758: ...ing menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STOP LIGHT SW CHECK a Read the STP signal on the hand held tester b Measure the voltage between terminals ST1 and body ground OK Brake Pedal STP Signal ST1 Voltage Depressed ON Below 1 5 V Released OFF 7 5 to 14 V OK Check for intermittent problems See page DI 295 NG 5 Check harness and connector between ECM and stop light switch See page IN 30 NG R...

Page 759: ... when the brake pedal is operated and released NG Check and repair stop light circuit See page BE 37 OK 2 Check STOP fuse PREPARATION Remove the STOP fuse from the instrument panel J B CHECK Check the continuity of the STOP fuse OK Continuity NG Check for short in all harness and components connected to STOP fuse OK 3 Check stop light switch See page BE 37 NG Replace stop light switch OK 758 ...

Page 760: ...gnition switch ON CHECK Check voltage between terminal STP and ST1 of ECM and body ground OK Brake Pedal STP Voltage ST1 Voltage Depressed 7 5 to 14 V Below 1 5 V Released Below 1 5 V 7 5 to 14 V OK Check for intermittent problems See page DI 295 NG 5 Check harness and connector between ECM and stop light switch See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78...

Page 761: ...ovide the proper throttle valve opening angle to obtain the target idle speed The ECM regulates the idle speed by opening and closing the throttle valve using the ETCS The TCM con cludes that the idle speed control ECM function is malfunctioning if 1 the actual idle RPM varies more than the specified amount or 2 a learning value of the idle speed control remains at the maximum or minimum five time...

Page 762: ...resent See page DI 295 Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection Criteria Threshold Either of the following conditions is met Condition 1 or 2 1 Frequency that both of the following conditions a and b are met 5 times or more a Engine RPM target engine RPM Less than 100 rpm or more than 200 rpm intake air temperature is 0 C 32 F or more Less than 100 rpm or more than 300 rpm intake ai...

Page 763: ...air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Are there any other codes besides P0505 being output PREPARATION a Connect the hand held tester or the OBD II scan tool to the DLC3 b Turn the ignition switch ON and push the hand held tester or the OBD II scan tool main switch ON c On the hand held tester or the OBD II scan tool enter the following m...

Page 764: ...E 2ZZ GE DI 565 2005 CELICA RM1131U 3 Check air induction system CHECK Check for vacuum leaks in air induction system NG Repair or replace air induction system OK Check electric throttle control system See page SF 39 763 ...

Page 765: ... Trouble Area P0560 Open in back up power source circuit S Open in back up power source circuit S EFI fuse S ECM HINT If DTC P0560 appears the ECM does not store other DTC MONITOR STRATEGY Related DTCs P0560 System voltage malfunction Required sensors components ECM Frequency of operation Continuous Duration 3 sec MIL operation Immediate 1 Sequence of operation None 1 The DTC is set immediately Th...

Page 766: ... engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check EFI fuse of engine room J B PREPARATION Remove the EFI fuse from the engine room J B CHECK Check the contin...

Page 767: ...move the ECM cover CHECK Measure the voltage between terminal BATT of the ECM con nector and body ground OK Voltage 9 to 14 V OK Replace ECM See page SF 78 NG 3 Check for open or short in harness and connector between ECM and EFI No 1 fuse EFI fuse and battery See page IN 30 NG Repair or replace harness or connector OK Check and replace engine room J B 766 ...

Page 768: ...oring The ECM sets a DTC if 1 outputs from the 2 CPUs are different and deviate from the standards 2 the sig nals to the throttle actuator deviate from the standards 3 a malfunction is found in the throttle actuator sup ply voltage and 4 any other ECM malfunction is found DTC No DTC Detecting Condition Trouble Area P0604 P0606 P0607 P0657 ECM malfunction S ECM MONITOR STRATEGY Related DTCs P0604 R...

Page 769: ...CPU reset 1 time or more b Difference between TP and APP learing values 0 4 V or more c Electronic throttle actuator OFF 2 CPU reset 2 times or more P0657 ETCS power supply when ignition switch is turned from OFF to ON 7 V or more INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is...

Page 770: ...ine revolution y 1 000 rpm c STA signal ON S Park neutral position switch A T S Clutch start switch M T S Starter relay circuit S Ignition switch S ECM MONITOR STRATEGY Related DTCs P0617 Starter signal error Required sensors components Main sensors components Starter signal Related sensors components Vehicle speed sensor Engine speed sensor Frequency of operation Continuous Duration 20 sec MIL op...

Page 771: ...A 2F 2F 2B ST AM2 MAIN FL MAIN W B B W B W IE1 1 4 5 Ignition Switch B R IK IC 11 9 IE4 EA1 4 1 EA1 14 W B B W B 1 1 2 B W B W B W W B W B IC1 3 6 IC1 B R W B 1 2 2 J3 J C IE A S1 S2 1 1 Park Neut ral Position Switch Clutch Start Switch Starter P1 I10 C11 1 A T 2 M T 9 6 1 2 1 2 AM2 ST2 DI 572 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U WIRING DIAGRAM 770 ...

Page 772: ...d tester 1 Check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter is operating OK Ignition Switch Position ON START STA Signal OFF ON OK Go to step 5 NG 2 Check ...

Page 773: ... 4 6 7 8 1Ω or less NG Replace ignition switch Go to next step 5 after the replacement OK 4 Check STA signal PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST ALL STARTER SIG CHECK Read the STA signal on the hand held tester while the starter is operating O...

Page 774: ...n the ignition switch ON and OBD II scan tool main switch ON c Clear DTC See page DI 295 d Drive the vehicle more than 40 km h 25 mph for 20 seconds or more CHECK Check DTC reoccur RESULT Display DTC Output Proceed to P0617 A No DTC output B A Replace ECM See page SF 78 B Check for intermittent problems See page DI 295 773 ...

Page 775: ... the voltage between terminal STA of the ECM connec tor and body ground during the engine cranking OK Voltage 0 V Ignition switch ON 6 V or more Engine cranking OK Go to step 5 NG 2 Check park neutral position switch or clutch start switch a Inspect the park neutral position switch A T See page DI 701 b Inspect the clutch start switch M T See page CL 2 NG Replace park neutral position switch or cl...

Page 776: ...ow 1Ω ON 2 3 4 6 7 Below 1Ω START 1 2 4 6 7 8 Below 1Ω NG Replace ignition switch Go to next step 5 after the replacement OK 4 Check voltage between terminal STA of ECM connector and body ground PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure the voltage between terminal STA of the ECM connec tor and body ground during the engine cranking OK Voltage 0 V Ignition swit...

Page 777: ... the ignition switch ON and OBD II scan tool main switch ON c Clear DTC See page DI 295 d Drive the vehicle more than 40 km h 25 mph for 20 seconds or more CHECK Check DTC reoccur RESULT Display DTC Output Proceed to P0617 A No DTC output B A Replace ECM See page SF 78 B Check for intermittent problems See page DI 295 776 ...

Page 778: ...t accurate ECM MONITOR STRATEGY Related DTCs P0630 VIN not programed Required sensors components Main sensors components ECM Related sensors components Frequency of operation Continuous Duration 0 5 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 295 Battery volta...

Page 779: ...DTC NOTICE If P0630 is present the VIN must be input to the ECM using the hand held tester However all DTCs are cleared automatically by the tester when the VIN is input If DTCs other than P0630 are present check them first NEXT 2 Input VIN with hand held tester See page DI 322 NEXT END 778 ...

Page 780: ...unication from body ECU b No communication from A C ECU S Body ECU S A C ECU S Communication bus INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up...

Page 781: ...MONITOR DESCRIPTION The ECM monitors the current through the electronic throttle motor and detects malfunctions or open circuit in the throttle motor based on the voltage of the current When the current deviates from the standard the ECM concludes that there is a fault in the throttle motor Or if the throttle valve is not functioning properly for example stuck ON the ECM concludes that there is a ...

Page 782: ...Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 295 P2102 Throttle motor ON Duty cycle ratio to open throttle actuator 80 Throttle actuator power supply 8 V Motor current change during the last 0 016 sec 0 2 A P2103 Throttle motor ON Either of the following conditions is met A or B A Throttle actuator power supply 8 V B Throttle actuator power ON TYPICAL MALFUN...

Page 783: ...ame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check throttle control motor PREPARATION Disconnect the throttle control motor connector CHEC...

Page 784: ... See page IN 30 NG Repair or replace harness or connector OK 3 Visually check throttle valve PREPARATION Remove the intake air connector CHECK Check between the throttle valve and the housing for foreign objects Also check if the valve can open and close smoothly NG Remove foreign objects and clean throttle body OK Replace ECM See page SF 78 783 ...

Page 785: ...112 Throttle motor locked during ECM order to close S Same as DTC No P2111 MONITOR DESCRIPTION The ECM concludes that there is a malfunction of the ETCS when the throttle valve remains at a fixed angle despite high drive current from the ECM The ECM will turn on the MIL and a DTC will be set FAIL SAFE If the Electronic Throttle Control System ETCS has a malfunction the ECM cuts off current to the ...

Page 786: ...ent See page DI 295 P2111 System guard ON Throttle motor current 2 A Throttle motor duty to close side 80 P2112 System guard ON Throttle motor current 2 A Throttle motor duty to open side 80 System guard Throttle actuator ON Throttle actuator duty calculation Executing Throttle position sensor Fail determined Throttle actuator current cut operation Not executing Throttle actuator power supply 4 V ...

Page 787: ...ck throttle valve PREPARATION Remove the intake air connector CHECK Check between the throttle valve and the housing for foreign objects Also check if the valve can open and close smoothly NG Remove foreign object and clean throttle body OK 2 Check if DTC outputs reoccur PREPARATION a Clear the DTC See page DI 295 b Start and warm up the engine c Run the engine d Fully depress and release the acce...

Page 788: ... For this reason when the voltage is low current to the motor is cut If repairs are made and the system has returned to normal turn the ignition switch OFF The ECM then allows current to flow to the motor and the motor can be restarted HINT This Electrical Throttle Control System ETCS does not use a throttle cable DTC No DTC Detection Condition Trouble Area P2118 Open in ETCS power source circuit ...

Page 789: ...ly If a pass condition is detected and then the ignition switch is turned OFF the fail safe operation will stop and the system will return to normal condition MONITOR STRATEGY Related DTCs P2118 Throttle actuator motor power supply line range check Low voltage Required sensors components Throttle actuator motor Frequency of operation Continuous Duration 0 8 sec MIL operation Immediate Sequence of ...

Page 790: ...19279 ECM BM E8 6 W R Battery 2A ETCS 2I 1 Engine Room J B No 1 and Engine Room R B No 1 B FL MAIN 1A Engine Room J B 1 1 B R 1 1 2 DIAGNOSTICS ENGINE 2ZZ GE DI 591 2005 CELICA RM1131U WIRING DIAGRAM 789 ...

Page 791: ...ot if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred 1 Check ETCS fuse PREPARATION Remove the ETCS fuse from the engine room R B No 1 CHECK Check the continuity of the ETCS fuse OK Continuity NG Check for short in all harness and components connected to ETCS fuse OK 2 Check voltage between terminal BM of ECM connector and body ground PREPARATION...

Page 792: ...ZZ GE DI 593 2005 CELICA RM1131U 3 Check for open and short in harness and connector between ECM and ETCS fuse ETCS fuse and battery See page IN 30 NG Repair or replace harness or connector OK Check engine room R B No 1 791 ...

Page 793: ...d to the target throttle position commanded by the ECM If the difference of these two values exceeds a specified limit the ECM interprets this as a fault in the ETCS Electronic Throttle Control System The ECM turns on the MIL and a DTC is set FAIL SAFE If the ETCS Electronic Throttle Control System has a malfunction the ECM cuts off current to the throttle control motor The throttle control valve ...

Page 794: ...on 1 or 2 1 Commanded closed TP current closed TP 0 3 V or more for 1 sec 2 Commanded open TP current open TP 0 3 V or more for 0 6 sec COMPONENT OPERATING RANGE Standard Value Commanded throttle position and current throttle position are nearly the same WIRING DIAGRAM Refer to DTC P2102 on page DI 582 INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan t...

Page 795: ... Output Proceed to Only P2119 is output A P2119 and other DTC are output B HINT If any other codes besides P2119 are output perform the troubleshooting for those codes first B Go to relevant DTC chart See page DI 335 A 2 Check if DTC outputs reoccur PREPARATION a Clear the DTC See page DI 295 b Start and warm up the engine c Run the engine at idle for 15 seconds or more d Perform the stall test Mo...

Page 796: ...dal Position Sensor Switch D Circuit High Input DTC P2125 Throttle Pedal Position Sensor Switch E Circuit DTC P2127 Throttle Pedal Position Sensor Switch E Circuit Low Input DTC P2128 Throttle Pedal Position Sensor Switch E Circuit High Input DTC P2138 Throttle Pedal Position Sensor Switch D E Voltage Correlation HINT This is the repair procedure for the accelerator pedal position sensor DIAKD 03 ...

Page 797: ...contact type The accelerator pedal position sensor is mounted on the accelerator pedal to detect the angle of the acceler ator pedal This sensor is electronically controlled and uses Hall effect elements In the accelerator pedal position sensor the voltage applied to terminals VPA and VPA2 of the ECM changes between 0 V and 5 V in proportion to the angle of the accelerator pedal The VPA is a signa...

Page 798: ... 3 45 V or less S Accelerator pedal position sensor S Open in EPA2 circuit S ECM P2138 Condition a or b continues for 2 0 sec or more a Difference between VPA and VPA2 is 0 02 V or less b VPA is 0 2 V or less and VPA2 is 0 5 V or less S VPA and VPA2 circuits are short circuited S Accelerator pedal position sensor S ECM HINT After confirming DTCs P2120 P2122 P2123 P2125 P2127 P2128 and P2138 use th...

Page 799: ...ion switch is turned OFF the fail safe operation will stop and the system will return to normal condition MONITOR STRATEGY Related DTCs P2120 Accelerator position sensor 1 VPA range check Fluttering P2122 Accelerator position sensor 1 VPA range check Low voltage P2123 Accelerator position sensor 1 VPA range check High voltage P2125 Accelerator position sensor 2 VPA2 range check Fluttering P2127 Ac...

Page 800: ...is 0 97 or more 0 5 V or less 2 VPA2 voltage when VPA1 is 0 2 to 3 45 V 4 8 V or more P2127 VPA2 voltage when VPA1 is 0 97 or more 0 5 V or less P2128 VPA2 voltage when VPA1 is 0 2 to 3 45 V 4 8 V or more P2138 Either of the following conditions is met Condition 1 or 2 1 Difference between VPA1 and VPA2 voltages 0 02 V or less 2 Both of the following conditions are met a and b a VPA1 voltage 0 2 V...

Page 801: ...bleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred Hand held tester 1 Connect hand held tester and read the voltage for accelerator pedal position sensor data PREPARATION a Connect the hand held tester to the DLC3 b Turn the ...

Page 802: ... See page IN 30 NG Repair or replace harness and connector OK 3 Check voltage between terminals VCPA and EPA and VCP2 and EPA2 of ECM terminals CHECK a Remove the ECM cover b Turn the ignition switch ON c Disconnect the accelerator pedal position sensor con nector CHECK Measure the voltage between terminals VCPA and EPA and VCP2 and EPA2 of the ECM connector OK Voltage 4 5 to 5 5 V NG Replace ECM ...

Page 803: ...hand held tester to the DLC3 b Clear the DTC by hand held tester or disconnect the battery terminals or remove the EFI fuses and ETCS fuses Clear DTCs c Start the engine d Drive the engine at idle for 15 sec or more CHECK Read the DTC output OK No DTC output OK System is OK NG Replace ECM See page SF 78 802 ...

Page 804: ...dal position sensor See page IN 30 NG Repair or replace harness or connector OK 2 Check voltage between terminals VCPA and EPA and VCP2 and EPA2 of ECM terminals CHECK a Remove the ECM cover b Turn the ignition switch ON c Disconnect the accelerator pedal position sensor con nector CHECK Measure the voltage between terminals VCPA and EPA and VCP2 and EPA2 of the ECM connector OK Voltage 4 5 to 5 5...

Page 805: ...TION a Connect the OBD II scan tool to the DLC3 b Disconnect the battery terminals or remove the EFI fuse and ETCS fuses Clear DTCs c Start the engine d Drive the engine at idle for 15 sec or more CHECK Read the DTC output OK No DTC output OK System is OK NG Replace ECM See page SF 78 804 ...

Page 806: ...ndard the ECM con cludes the accelerator pedal position sensor has a malfunction The ECM turns on the MIL and a DTC is set FAIL SAFE The accelerator pedal position sensor has two main and sub sensor circuits If a malfunction occurs in ei ther of the sensor circuits the ECM detects the abnormal signal voltage difference between the two sensor circuits and switches to limp mode In limp mode the rema...

Page 807: ...e OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other data from the time when a malfunction occurred Hand held tester 1 Connect hand held tester and read the voltage fo...

Page 808: ...609 2005 CELICA RM1131U 2 Check for open and short in harness and connector between accelerator pedal position sensor and ECM See page IN 30 NG Repair or replace harness or connector OK Replace accelerator pedal position sensor 807 ...

Page 809: ...ge between terminals VPA and EPA VPA2 and EPA2 of the ECM connectors OK Accelerator Pedal Position Tester Connection Tester Connection VPA EPA VPA2 EPA2 Released 0 5 to 1 1 V 1 2 to 2 0 V Depressed 2 6 to 4 5 V 3 4 to 5 3 V OK Replace ECM See page SF 78 NG 2 Check for open and short in harness and connector between accelerator pedal position sensor and ECM See page IN 30 NG Repair or replace harne...

Page 810: ...t Low Bank 1 DTC P2433 Secondary Air Injection System Air Flow Pressure Sensor Circuit High Bank 1 CIRCUIT DESCRIPTION To accelerate the activation of catalyst when warming up the engine the air injection system pumps the sec ondary air to the exhaust manifold The secondary air is supplied by the air pump and is pumped to the ex haust manifold through the air switching valve Open and close movemen...

Page 811: ...CM observes the pressure in the secondary air passage using the pressure sensor located on the air switching valve in the secondary air injection system If there is a defect in the sensor or the sensor circuit the voltage level will deviate from the normal operating range the ECM in terprets this deviation as a defect in the pressure sensor circuit and sets a DTC MONITOR STRATEGY Related DTCs P243...

Page 812: ...able Check the monitor result and test values after performing the monitor drive pattern see page DI 326 S TID Test Identification Data is assigned to each emissions related component S TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit S CID C...

Page 813: ...R 1 2 GR R 7 EA2 GR R A19 Air Pump Relay 1 2 3 4 B 1 EC1 B A18 Air Pump Motor M W GR B W EN EO EB W B 2H 7 2F 12 2I 1 3 2 1 5 EFI Relay EFI 2A 1 2C 3 EFI No 2 EFI No 1 B R FL MAIN Battery B 1A 1 A AMP 1 B R B W 2 1 2F 19 Engine Room R B No 1 and J B No 1 Engine Room J B DI 614 DIAGNOSTICS ENGINE 2ZZ GE 2005 CELICA RM1131U WIRING DIAGRAM 812 ...

Page 814: ... AIR PRESS on the hand held tester indicate the same conditions as the chart below NOTICE This test allows the technician to operate the VSV for only 5 seconds If you perform the test again more than 30 seconds interval must be required after the previous test is done Tester Operation Specified Condition 2ND AIR PRESS 3 SECONDARY AIR 1 SECOND AIR VSV 2 VSV is ON ON ON 2 5 kPa or more VSV is OFF OF...

Page 815: ... tester to the DLC3 on the vehicle c Turn the ignition switch ON and push the hand held tes ter main switch ON Do not start engine d Enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST 2ND AIR PRESS CHECK Check that the pressure displayed on the hand held tester fluc tuates when applying the pressure to the pressure sensor with the pressure gauge NG Replace pressure sensor See page EC 14...

Page 816: ...N To accelerate the activation of catalyst when warming up the engine the air injection system pumps the sec ondary air to the exhaust manifold by pressure The secondary air is supplied by the air pump and it is pumped to the exhaust manifold through the air switching valve Open and close movement of the air switch ing valve is regulated by the vacuum switching valve VSV The air pump and the air s...

Page 817: ... located on the air switching valve in the secondary air injection system The sensor detects an exhaust pressure in the second ary air passage If the ECM receives the pulsation signal from the sensor despite the ECM ordering the VSV to close the air switching valve or if the ECM has not received the signal from the sensor despite the ECM ordering the VSV to open the valve the ECM interprets this a...

Page 818: ...ification Data is assigned to each emissions related component S TLT Test Limit Type If TLT is 0 the component is malfunctioning when the test value is higher than the test limit If TLT is 1 the component is malfunctioning when the test value is lower than the test limit S CID Component Identification Data is assigned to each test value S Unit Conversion is used to calculate the test value indicat...

Page 819: ... the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P2440 or P2441 A P2440 P2441 and other DTCs B HINT If any other codes besides P2440 or P2441 are output perform the troubleshooting for those DTCs first B Go...

Page 820: ...ng the YES button on the tester HINT When operating the VSV in the secondary air system the air pump is also operated at the same time CHECK Put your hand at the disconnected hose end and check that the exhaust gas pressure pulsation is applied to your hand when turning on the VSV for air switching valve with the ACTIVE TEST And also check that the exhaust gas pressure pulsation is not applied to ...

Page 821: ...e No 1 for blockage or damage NG Repair or replace air injection system No 1 hose OK 4 Check stored DTC PREPARATION a Connect the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menus DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTC using the hand held tester Display DTC Output Proceed to P2440 A P2441...

Page 822: ... valve is correctly installed d Check that there is air flow in the check valve from the VSV to the engine Also check that there is no air flow in the opposite side NG Repair or replace vacuum hose and check valve OK 6 Check air switching valve See page EC 12 NG Replace air switching valve OK 7 Check vacuum switch valve See page EC 12 NG Replace vacuum switching valve OK 8 Check for open and short...

Page 823: ...ester to the DLC3 on the vehicle c Turn the ignition switch ON and push the hand held tes ter main switch ON Do not start engine d Enter the following menus DIAGNOSIS ENHANCED OBD II DATA LIST 2ND AIR PRESS CHECK Check that the pressure displayed on the hand held tester fluc tuates when applying the pressure to the pressure sensor with the pressure gauge NG Replace pressure sensor OK Replace ECM S...

Page 824: ... the OBD II scan tool main switch ON CHECK Read the DTCs RESULT Display DTC output Proceed to P2440 or P2441 A P2440 P2441 and other DTCs B HINT If any other codes besides P2440 or P2441 are output perform the troubleshooting for those DTCs first B Go to DTC chart See page DI 335 A 2 Check stored DTC CHECK Read the DTC using the OBD II scan tool Display DTC Output Proceed to P2440 A P2441 B A Go t...

Page 825: ...m hose and check valve CHECK a Check each vacuum hose connection between the pres sure sensor and air switching valve the air switching valve and the VSV and the VSV and intake manifold b Inspect the vacuum hose for blockage or damage c Check that check valve is correctly installed d Check that there is air flow in the check valve from the VSV to the engine Also check that there is no air flow in ...

Page 826: ...njection system See page IN 30 NG Repair or replace harness or connector OK 8 Inspect ECM air voltage PREPARATION a Connect the pressure gauge to the air pressure sensor as shown in the illustration b Turn the ignition switch ON Do not start engine CHECK Check for voltage change between terminals AIP and E2 of the ECM connector when applying the pressure to the pressure sensor with the pressure ga...

Page 827: ...injection system piping S Pressure sensor S Open or short in pressure sensor circuit S ECM MONITOR DESCRIPTION The ECM observes the pressure in the secondary air passage using the pressure sensor located on the air switching valve in the secondary air injection system The sensor measures the pressure in the secondary air passage and sends a signal to the ECM If the pressure level from the sensor h...

Page 828: ...jection MONITOR RESULT Refer to page DI 295 for detailed information The test value and test limit information are described as shown in the following table Check the monitor result and test values after performing the monitor drive pattern see page DI 326 S TID Test Identification Data is assigned to each emissions related component S TLT Test Limit Type If TLT is 0 the component is malfunctionin...

Page 829: ...t the hand held tester to the DLC3 b Turn the ignition switch ON and push the hand held tester main switch ON c Enter the following menu DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs RESULT Display DTC output Proceed to P2444 or P2445 A P2444 P2445 and other DTCs B HINT If any other codes besides P2444 or P2445 is output perform the troubleshooting for those DTCs first B Go ...

Page 830: ...NDARY AIR SECOND AIR VSV and 2ND AIR PRESS on the hand held tester indi cate the same conditions as the chart below NOTICE This test allows the technician to operate the VSV for only 5 seconds If you perform the test again more than 30 seconds interval must be required after the previous test is done Tester Operation Specified Condition SECONDARY AIR 1 SECOND AIR VSV 2 2ND AIR PRESS 3 VSV is ON ON...

Page 831: ...eed to P2444 A P2445 B A Go to step 10 B 4 Check vacuum hose CHECK a Check the vacuum hose connection between the pressure sensor and air switching valve b Inspect the vacuum hose for blockage or damage NG Repair or replace vacuum hose OK 5 Check connection of secondary air injection system piping CHECK a Check that all the pipes and hoses between the air pump and air switching valve are securely ...

Page 832: ...e resistance in the A AMP fuse OK Below 1 Ω NG Check for short in all harnesses and compo nents connected fuse OK 7 Check air pump relay See page EC 17 NG Replace air pump relay OK 8 Check voltage of air pump motor power source a Disconnect the air pump motor connector b Measure voltage between terminal 4 of the air pump as sembly connector and body ground Standard 9 to 14 V NG Repair air pump pow...

Page 833: ... wire harness side con nectors Standard Check for open Tester Connection Specified Condition Air Pump Assembly A22 2 Body ground Below 1 Ω c Reconnect the air pump assembly connector NG Repair or replace harness or connector OK 10 Inspect air pump assy See page EC 12 NG Replace air pump assy See page EC 14 OK 11 Check for open and short in harness and connector between ECM and air pump relay See p...

Page 834: ...er to the DLC3 on the vehicle c Turn the ignition switch ON and push the hand held tes ter main switch ON Do not start engine d Enter the following menu DIAGNOSIS ENHANCED OBD II DATA LIST 2ND AIR PRESS e Check that the pressure displayed on the hand held tes ter fluctuates when applying the pressure to the pressure sensor with the pressure gauge NG Replace pressure sensor OK Replace ECM See page ...

Page 835: ... switch ON CHECK Read the DTCs RESULT Display DTC output Proceed to P2444 or P2445 A P2444 P2445 and other DTCs B HINT If any other codes besides P2444 or P2445 are output perform the troubleshooting for those DTCs first B Go to DTC chart See page DI 335 A 2 Check stored DTC Read the DTC using the OBD II scan tool Display DTC Output Proceed to P2444 A P2445 B A Go to step 9 B 3 Check vacuum hose N...

Page 836: ...urely connected b Inspect the pipe and hoses for blockage or damage NG Repair or replace secondary air injection sys tem piping OK 5 Inspect A AMP fuse PREPARATION Remove the A AMP fuse from the engine room R B CHECK Check the resistance in the A AMP fuse OK Below 1 Ω NG Check for short in all harnesses and compo nents connected to fuse OK 6 Check air pump relay See page EC 17 NG Replace air pump ...

Page 837: ...mbly connector and body ground Standard 9 to 14 V NG Repair air pump power source circuit OK 8 Check for open in harness and connector between air pump motor and body ground NG Repair or replace harness or connector OK 9 Check air pump assy See page EC 12 NG Replace air pump assy See page EC 14 OK 10 Check for open and short in harness and connector between ECM and air pump relay See page IN 30 NG...

Page 838: ...he pressure gauge to the pressure sensor as shown in the illustration b Turn the ignition switch ON Do not start engine c Check for voltage changes between terminals AIP and E2 of the ECM connector when applying the pressure to the pressure sensor with the pressure gauge NG Replace pressure sensor OK Replace ECM See page SF 78 837 ...

Page 839: ...vances shims under the high lift cam followers using engine oil pressure Switching to the high lift cam increases the valve lift as well as the intake air volume and exhaust capacity These changes increase the engine s power output When the engine RPM is 6 000 rpm or more the ECM increases the OCV control signal duty ratio and it opens the oil passage to the VVTL i actuator The engine oil pressure...

Page 840: ...sis signal Fail WIRING DIAGRAM INSPECTION PROCEDURE HINT Read freeze frame data using the hand held tester or the OBD II scan tool Freeze frame data records the engine conditions when a malfunction is detected When troubleshooting freeze frame data can help deter mine if the vehicle was running or stopped if the engine was warmed up or not if the air fuel ratio was lean or rich as well as other da...

Page 841: ...by the hand held tester OK Tester Operation Specified Condition VVTL CTRL B1 is OFF OCV is OFF Normal engine speed VVTL CTRL B1 is ON OCV is ON Rough engine speed or engine stalled OK Check for intermitten problems See page DI 295 NG 2 Check operation of OCV for VVTL PREPARATION Start the engine and warmed it up CHECK Check the engine speed at 1 and 2 1 Disconnect the C2 camshaft timing oil contro...

Page 842: ...e between terminals OVL and OVL of ECM connector See page DI 333 NG Replace ECM See page SF 78 OK 4 Check for open and short in harness and connector between OCV for VVTL and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 841 ...

Page 843: ... voltage between the terminals of the camshaft timing oil control valve RESULT Proceed to Check 1 Check 2 A Normal engine speed Rough idle or engine stall B Conditions other than above OK Engine stalled NG Replace OCV for VVTL OK 2 Check voltage between terminals OVL and OVL of ECM connector See page DI 333 NG Replace ECM See page SF 78 OK 3 Check for open and short in harness and connector betwee...

Page 844: ...tput When the engine RPM is 6 500 rpm or more the ECM increases the OCV control signal duty ratio and it opens the oil passage to VVTL i actuator The engine oil pressure powered actuator advances the cam fol lower shims and valves begin using the high lift cam The VVTL i oil pressure switch senses the engine oil pressure applied to the VVTL i system and the ECM judges which cam standard cam or hig...

Page 845: ...LFUNCTION THRESHOLDS Detection Criteria Threshold Case 1 Cam does not change to standard cam Oil pressure switch for VVTL under standard cam condition ON Oil pressure is applied to VVTL i system for 5 sec or more Case 2 Cam does not change to high lift cam Oil pressure switch for VVTL under high lift cam condition OFF Oil pressure is not applied to VVTL i system for 1 sec or more COMPONENT OPERATI...

Page 846: ... VVTL CTRL B1 is ON OCV is ON Rough engine speed or engine stalled OK Check for intermitten problems See page DI 295 NG 2 Check oil pressure switch for VVTL PREPARATION a Start the engine and warm it up b Connect the hand held tester to the DLC3 c Turn the ignition switch ON and push the hand held tester main switch ON d Enter the following menu DIAGNOSIS ENHANCED OBD II ACTIVE TEST ALL VVTL CTRL ...

Page 847: ...ssure switch for VVTL and ECM See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 4 Check oil control valve filter PREPARATION a Remove the generator See page CH 7 b Remove the oil control valve filter CHECK Check the oil control valve filter Confirm that the filter is clear NG Replace oil control valve filter OK 846 ...

Page 848: ...d at 1 and 2 1 Disconnect the C2 camshaft timing oil control valve connector 2 Apply the battery voltage between the terminals of the camshaft timing oil control valve RESULT Proceed to Check 1 Check 2 A Normal engine speed Rough idle or engine stall B Conditions other than above OK Engine stalled B Replace OCV for VVTL A Check for intermittent problems See page DI 295 847 ...

Page 849: ...N a Start the engine and warm it up b Disconnect the OCV for VVTL connector c Maintain engine speed at 6 500 rpm CHECK Measure continuity between the oil pressure switch and body ground when applying battery voltage be tween terminals of the OCV OK VVTL system is OFF OCV is OFF No continuity VVTL system is ON OCV is ON Continuity NG Replace oil pressure switch OK 2 Check for open and short in harn...

Page 850: ...ear NG Replace oil control valve filter OK 4 Check operation of OCV for VVTL PREPARATION Start the engine and warm it up CHECK Check the engine speed at 1 and 2 1 Disconnect the C2 camshaft timing oil control valve connector 2 Apply battery voltage between the terminals of the OCV RESULT Proceed to Check 1 Check 2 A Normal engine speed Rough idle or engine stall B Conditions other than above OK En...

Page 851: ...t CIRCUIT DESCRIPTION When the ignition switch is turned ON battery voltage is applied to terminal IGSW of the ECM The ECM MREL output signal causes current to flow to the coil closing the contacts of the EFI relay and supplying power to terminal B of the ECM If the ignition switch is turned OFF the ECM holds the EFI relay ON for a maximum of 2 seconds to allow for the initial setting of the throt...

Page 852: ...als B and E1 of the ECM con nector OK Voltage 9 to 14 V OK Replace ECM See page SF 78 NG 2 Check for open in harness and connector between terminal E1 of ECM and body ground See page IN 30 NG Repair or replace harness or connector OK 3 Check voltage between terminals IGSW and E1 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure voltage between terminal...

Page 853: ... ECM See page IN 30 5 Check voltage between terminals MREL and E1 of ECM connector PREPARATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure voltage between terminals MREL and E1 of the ECM connector OK Voltage 9 to 14 V OK Repace ECM See page SF 78 NG 6 Check EFI fuse PREPARATION Remove the EFI fuse from the engine room J B CHECK Check continuity of EFI fuse OK Continuity NG ...

Page 854: ... short in all the harness and compo nents connected to EFI No 1 fuse OK 8 Check EFI main relay Marking EFI See page SF 56 NG Replace EFI main relay OK 9 Check for open and short in harness and connector between EFI relay and ECM EFI relay and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace harness and connector between terminal B of ECM and battery positiv...

Page 855: ...am below when the engine is cranked current flows from terminal ST2 of the ignition switch to the starter relay coil and also current flows to terminal STA of the ECM STA signal When the STA signal and NE signal are input to the ECM Tr is turned ON current flows to the coil of the circuit opening relay the relay switches on power is supplied to the fuel pump and the fuel pump operates While the NE...

Page 856: ...EL FC 8 E9 GR G R EB 11 FL MAIN Battery 10 12 2F 10 2F 11 2F C O PN Relay 1 EFI Relay W B EFI II2 L B W B 2 5 3 1 2 5 3 7 2H 1 2A 4 5 BJ L B B R F17 Fuel Pump A W B E9 DIAGNOSTICS ENGINE 2ZZ GE DI 657 2005 CELICA RM1131U WIRING DIAGRAM 855 ...

Page 857: ...IS ENHANCED OBD II ACTIVE TEST FUEL PUMP SPD CHECK Check if operating sounds can be heard while operating the relay with the hand held tester OK Operating sounds can be heard from the relay OK Go to step 5 NG 2 Check circuit opening relay Marking C OPN See page SF 57 NG Replace circuit opening relay OK 3 Check voltage between terminal FC of ECM and body ground PREPARATION a Remove the ECM cover b ...

Page 858: ...y Marking C OPN and ignition switch See page IN 30 NG Repair or replace harness or connector OK 5 Check fuel pump See page SF 6 NG Repair or replace fuel pump OK 6 Check for open in harness and connector between circuit opening relay Mark ing C OPN and fuel pump fuel pump and body ground See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 857 ...

Page 859: ... ground b Check for fuel pressure in the fuel inlet hose when it is pinched off OK There is pressure in fuel inlet hose HINT At this time you will hear a fuel return flowing noise OK Proceed to next circuit inspection shown on problem symptoms table See page DI 332 NG 2 Check operation of circuit opening relay Marking C OPN CHECK When connecting between terminal FC of the ECM connector and the bod...

Page 860: ...ATION a Remove the ECM cover b Turn the ignition switch ON CHECK Measure voltage between terminal FC of the ECM and body ground OK Voltage 9 to 14 V OK Replace ECM See page SF 78 NG 5 Check for open and short in harness and connector between circuit opening relay Marking C OPN and ECM circuit opening relay Marking C OPN and ignition switch See page IN 30 NG Repair or replace harness or connector O...

Page 861: ...ump See page SF 6 NG Repair or replace fuel pump OK 7 Check for open in harness and connector between circuit opening relay Mark ing C OPN and fuel pump fuel pump and body ground See page IN 30 NG Repair or replace harness or connector OK Replace ECM See page SF 78 860 ...

Page 862: ...ound that illuminates the MIL MIL operation is checked visually It should be illuminated when the ignition is first turned on If the MIL is off all of the time or on all of the time use the procedure below to troubleshoot it The MIL is used to indicate the ECM s detection of vehicle mal function Follow this procedure using the hand held tester or an OBD II scan tool to determine the cause of the p...

Page 863: ...TCs See page DI 295 d Clear the DTCs See page DI 295 CHECK Check that MIL is not illuminated OK MIL is not illuminated OK Repair circuit indicated by output DTC See page DI 335 NG 2 Check for short in wire harness PREPARATION a Disconnect the E9 ECM connector b Turn the ignition switch ON CHECK Check that MIL is not illuminated OK MIL is not illuminated OK Replace ECM See page SF 78 NG Check and r...

Page 864: ...turning the ignition switch ON OK MIL is illuminated OK System OK NG 4 Check combination meter assy MIL circuit See the combination meter troubleshooting on page See page BE 50 NG Repair or replace bulb or combination meter as sembly OK Check and repair harness and connector be tween combination meter and ECM See page IN 30 863 ...

Page 865: ...s not occur symptom occurs Symptom Simulation DTC Chart Problem Symptom Confirmation Basic Inspection Mechanical System Test Manual Shifting Test NG OK Code NG OK NG NG NG NG OK Chapter 3 Off Vehicle End DTC Check OK OK OK Identification of Problem SO D Main Switch O D OFF Indicator Light Circuit SE Shift Main Switch Circuit Check Circuit Inspection Parts Inspection Repair Confirmation Test Chapte...

Page 866: ...7 2005 CELICA RM1131U PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transaxle assy engine assy or the ECM See page DI 669 HINT Initialization can not be completed by only disconnecting the battery terminal 865 ...

Page 867: ...ove Any position Particular position No down shift O D 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive position Slip or shudder No kick down Others DTC Check 1st Time 2nd Time Check Item Normal code Malfunction code DTC Normal code Malfunction code DTC Malfunction Indicator Lamp Normal Remains ON How Often Does Problem Occur DI 668 DIA...

Page 868: ...fect vehicle emissions In addition to the MIL lighting up when a malfunction is detected the applicable DTCs pre scribed by SAE J2012 are recorded in the ECM memory See page DI 335 If the malfunction does not occur in 3 consecutive trips the MIL goes off but the DTCs remain recorded in the ECM memory S To check the DTCs connect an OBD II scan tool or hand held tester to DLC3 on the vehicle The OBD...

Page 869: ...b Inspect the DLC3 The vehicle s ECM uses ISO 9141 2 for communication The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141 2 format Tester connection Condition Specified condition 7 Bus ę Line 5 Signal ground During communication Pulse generation 4 Chassis Ground Body Always 1 Ω or less 5 Signal Ground Body Always 1 Ω or less 16 B Body Always 9 to 14 V HINT If your di...

Page 870: ...ote them down 1 Prepare an OBD II scan tool complying with SAE J1978 or hand held tester 2 Connect the OBD II scan tool or hand held tester to DLC3 at the lower of the instrument panel 3 Turn the ignition switch ON and turn the OBD II scan tool or hand held tester switch ON 4 Use the OBD II scan tool or hand held tester to check the DTCs and freeze frame data and note them down For operating instr...

Page 871: ...item DIAGNOSIS ENHANCED OBD II DTC INFO CLEAR CODES YES button HINT When operating the OBD II scan tool complying with SAE J1978 or hand held tester to erase the codes the DTCs and freeze frame data will be erased See the OBD II scan tool s instruction book for operating instructions d When not using the OBD II scan tool or hand held tester Clearing the DTCs Disconnect the battery terminal or remo...

Page 872: ... held tester 4 Connect the hand held tester to DLC3 at the lower side of the instrument panel 5 Turn the ignition switch ON and switch the hand held tester ON 6 Switch the hand held tester from Normal mode to Check mode Check that the MIL flashes 7 Start the engine MIL goes out after the engine starts 8 Simulate the conditions of the malfunction de scribed by the customer NOTICE Leave the ignition...

Page 873: ...item DIAGNOSIS ENHANCED OBD II DTC INFO CLEAR CODES YES button HINT When operating the OBD II scan tool complying with SAE J1978 or hand held tester to erase the codes the DTCs and freeze frame data will be erased See the OBD II scan tool s instruction book for operating instructions c When not using the OBD II scan tool or hand held tester Clearing the DTCs Disconnect the battery terminal or remo...

Page 874: ...t Lever Position is S L 1st S 2 1st or 2nd S D O D OFF 1st 2nd or 3rd S D O D ON 1st 2nd 3rd or 4th O D LOCK UP SOL Lock Up Solenoid Status ON or OFF S Lock Up ON S Except Lock Up OFF PNP SW NSW PNP SW Status ON or OFF Ignition Key position is START ON Except START OFF LOW PNP SW Status ON or OFF Shift lever position is L ON Except L OFF The shift lever position and these values are different ther...

Page 875: ...ressure Vehicle Condition S Vehicle Stopped S IDL ON Others ON Line pressure up OFF No action normal operation 6 DEFINITION OF TERMS Term Definition Monitor description Description of what the ECM monitors and how it detects malfunctions monitoring purpose and its details Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic Typic...

Page 876: ...t Vacuum sensor Manifold air pressure sensor Internal control module Control module Engine control ECU PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control VSV for CCV Canister close valve VSV for canister control Evaporative emissions canister vent valve VSV for EVAP Vacuum switching valve assembly No 1 EVAP VSV Purge VSV Evaporative emissions can...

Page 877: ...luid temperature sensor Electronic controlled automatic transmission ECT Electronically controlled automatic Intermediate shaft speed sensor A Counter gear speed sensor Output speed sensor Output shaft speed sensor Input speed sensor Input turbine speed sensor A Speed sensor NT Turbine speed sensor Input turbine speed sensor PNP switch NSW Park neutral position switch Pressure control solenoid Tra...

Page 878: ...r the following DTCs are not present Monitor Disablement List HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed 877 ...

Page 879: ...A21571 DI 680 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U 878 ...

Page 880: ...A21572 A22718 A22768 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E DI 681 2005 CELICA RM1131U 879 ...

Page 881: ...A21573 DI 682 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U 880 ...

Page 882: ...A21575 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E DI 683 2005 CELICA RM1131U 881 ...

Page 883: ...A21576 DI 684 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U Note 1 Without input speed sensor Note 2 With input speed sensor 882 ...

Page 884: ...gear and check for abnormal noises and vibration HINT The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential torque converter clutch etc 4 Check kick down operation While driving in the D position 2nd 3rd and O D gears check that the possible kick down ve hicle speed limits for 2 1 3 2 and O D 3 kick down...

Page 885: ...rator pedal and check the engine braking effect 3 Check for abnormal noises during acceleration and deceleration e R position test Shift into the R position lightly depress the accelerator pedal and check that the vehicle moves back ward without any abnormal noise or vibration CAUTION Before conducting this test ensure that the test area is free from people and obstruction f P position test Stop t...

Page 886: ... posi tions from P to L position and then shift into P posi tion 5 With the engine idling check the fluid level Add fluid up to the COOL level on the dipstick 6 Check the fluid level at the normal operating tem perature 70 to 80 C 158 to 176 F and add as necessary NOTICE Do not overfill d Check the fluid leaks Check for leaks in the transaxle If there are leaks it is necessary to repair or replace...

Page 887: ...in lbf For continuity inspection of the park neutral position switch see page DI 701 g Check the idle speed Idle speed 650 50 rpm In N position and air conditioner OFF 12 MECHANICAL SYSTEM TESTS a Measure the stall speed The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions NOTICE S Do the test at normal opera...

Page 888: ...e lapse or lag before the shock can be felt This is used for checking the condition of the O D direct clutch forward clutch and 1st reverse brake NOTICE S Do the test at normal operating fluid temperature 50 to 80 C 122 to 176 F S Be sure to allow 1 minute interval between tests S Take 3 measurements and take the average value 1 Connect an OBD II scan tool or hand held tester to DLC3 2 Fully apply...

Page 889: ...brake pedal and shift into D position 7 Measure the line pressure when the engine is idling 8 Depress the accelerator pedal all the way down Quickly read the highest line pressure when engine speed reaches stall speed 9 In the same manner do the test in R position Specified line pressure Condition D position kPa kgf cm2 psi R position kPa kgf cm2 psi Idling 372 to 412 3 8 to 4 2 54 to 59 672 to 74...

Page 890: ...peration it is assumed that there is a mechanical problem a Turn the ignition switch OFF b Disconnect the solenoid wire connector c Warm up the engine d Drive the vehicle e Check the transaxle operation when the shift lever is moved into L 2 and D ranges Standard Shift Lever Operation L to 2 No shift Not change 2 to D No shift Not change D to 2 No shift Not change 2 to L No shift Not change f Turn...

Page 891: ... characteristics Therefore when the automatic transaxle assy engine assy or ECM has been replaced it is necessary to reset the memory so that the ECM can memorize the new information Reset procedure is as follows a Turn the ignition switch off b Connect the hand held tester to the DLC3 c Turn the ignition switch to the ON position and push the hand held tester main switch on d Select the item DIAG...

Page 892: ...f P0717 DI 713 Turbine Speed Sensor Circuit No Signal S Open or short in speed sensor NT circuit S Speed sensor NT S ECM S Automatic transaxle assembly F f P0724 DI 716 Brake Switch B Circuit High S Short in stop light switch circuit S Stop light switch S ECM F f P0741 DI 718 Torque Converter Clutch Sole noid Performance Shift Solenoid Valve DSL S Shift solenoid valve DSL is stuck open or closed S...

Page 893: ...F f P2716 DI 738 Pressure Control Solenoid D Electrical Shift Solenoid Valve SLT S Open or short in shift solenoid valve SLT circuit S Shift solenoid valve SLT S ECM F f P2769 DI 742 Torque Converter Clutch Sole noid Circuit Low Shift Solenoid Valve DSL S Short in shift solenoid valve DSL circuit S Shift solenoid valve DSL S ECM F f P2770 DI 742 Torque Converter Clutch Sole noid Circuit High Shift...

Page 894: ...ch DLC3 Counter Gear Speed Sensor NC Shift Solenoid Valve SLT Shift Solenoid Valve SL1 ECM Input Turbine Speed Sensor NT ATF Temperature Sensor Park Neutral Position Switch Shift Solenoid Valve DSL Shift Solenoid Valve SL2 Shift Solenoid Valve S4 Vehicle Speed Sensor DIAGNOSTICS AUTOMATIC TRANSAXLE U240E DI 695 2005 CELICA RM1131U PARTS LOCATION 893 ...

Page 895: ...E1 E12 1 R B BR IG switch ON and Shift lever R position 10 14 V IG switch ON and Shift lever other than R position Below 1 V SPD E8 17 E1 E12 1 W R BR IG switch ON and Turn one front wheel slowly Pulse signal is output Below 1 4 6 V SFTD E8 21 E1 E12 1 P L BR IG ON and Down transmission shift switch pressed Below 1 V IG ON and Down transmission shift switch repressed 10 14 V SFTU E8 22 E1 E12 1 L ...

Page 896: ...switch ON Below 1 V 1st or 2nd gear 10 14 V 3rd or O D gear Below 1 V SL1 E11 19 SL1 E11 18 G R V IG switch ON 10 14 V 1st or 2nd gear 10 14 V 3rd or O D gear Below 1 V NC E11 26 NC E11 34 P B G O Engine is running Below 1 and 4 5 V NT E11 27 NT E11 35 W L B R Engine is running Below 1 and 4 5 V 895 ...

Page 897: ...ircuits check and re place the ECM Chapter 1 Electronic circuit matrix chart Symptom Suspected Area See page No up shift A particular gear from 1st to 3rd gear is not up shifted ECM IN 30 No up shift 3rd O D 2 O D main switch circuit 3 ECM DI 746 IN 30 No down shift O D 3rd ECM IN 30 No down shift A particular gear from 3rd to 1st gear is not down shifted ECM IN 30 No lock up or No lock up off ECM...

Page 898: ...ift valve L No down shift 3rd 2nd 2 3 shift valve L No down shift 2nd 1st 1 2 shift valve L No lock up or No lock up off 1 Lock up relay valve 2 Off vehicle repair matrix chart L Harsh engagement N D 1 C1 accumulator 2 Off vehicle repair matrix chart L Harsh engagement N R 1 C2 accumulator 2 Off vehicle repair matrix chart L Harsh engagement Lock up 1 Lock up relay valve 2 Off vehicle repair matri...

Page 899: ...3 No 1 one way clutch F1 L L L Harsh engagement N R 1 Direct clutch C2 2 1st reverse brake B2 L L Harsh engagement Lock up Torque converter clutch AX 36 Slip or shudder Forward position After warm up 1 Torque converter clutch 2 Forward clutch C1 3 Direct clutch C2 4 U D brake C3 5 No 1 one way clutch F1 6 U D one way clutch F2 AX 36 L L L L L Slip or shudder R position 1 Direct clutch C2 2 1st rev...

Page 900: ...x communication circuit S ECM MONITOR DESCRIPTION The park neutral position switch detects the shift lever position and sends a signal to the ECM For security the park neutral position switch detects the shift lever position so that engine can be started only when the vehicle is in P or N shift position When the park neutral position switch sends more than one signal at a time from switch position...

Page 901: ...umber of the following signal input at the same time 2 or more P switch ON R switch N switch D switch 2 switch L switch Condition B When shift lever is in M position one of following conditions is met P switch ON R switch N switch 2 switch L switch COMPONENT OPERATING RANGE Parameter Standard value Park neutral position switch The park neutral position switch sends only one signal to the ECM 900 ...

Page 902: ... LG R LG R LG R LG R C12 C12 C13 C13 MPX MPX TX 18 12 3 B6 16 4 B7 SG4 MPX1 Body ECU R L W R 4 O3 O D MAIN SW 5 8 4 1 RB RL DL R L R B B O 2C 2C 2C 19 6 17 IF 2A 2E ALT 1 2 Engine Room J B 1 1 2 AM1 IG1 I10 Ignition SW W L R IA IK IK AM1 5 3 C 6 1 5 8 W B 2 1 II 12 IB 7 BK UP LP IG1 Relay 7 2 3 2F 2F 2F 6 22 3 R L 1 P L P L O Y B EA3 EA3 EA3 EA3 Instrument Panel J B DIAGNOSTICS AUTOMATIC TRANSAXLE...

Page 903: ...R B R AM2 ST2 I10 Ignition Switch 4 5 IE1 1 B W B W 1 1 1 2 ST RELAY W B EA1 14 B B 9 6 P1 Park Neutral Position Switch W B 4 EA1 B W IE4 1 B W IC1 3 6 W B IC1 W B A J3 J C IE Engine Room J B Engine Room J B DI 704 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U 902 ...

Page 904: ...e combination meter when shift lever is moved to D range and M range OK Shift Lever Position Specified Condition M M indicator light comes on Except M M indicator light goes off NG Go to step 2 OK Go to step 4 2 Check the E shift main switch circuit See page DI 752 NG Repair E shift main switch circuit OK 3 Check multiplex communication circuit See page DI 1184 NG Repair multiplex communication ci...

Page 905: ...A hand held tester to the DLC3 c Turn the ignition switch ON and TOYOTA hand held tes ter main switch ON CHECK Shift lever into the P R N D 2 and L positions and read the NSW REVERSE 2ND DRIVE and LOW signals on the TOYO TA hand held tester OK Shift position Signal 2 2ND OFF ON L LOW OFF ON D DRIVE OFF ON R REVERSE OFF ON P N NSW OFF ON When not using TOYOTA hand held tester PREPARATION Turn the i...

Page 906: ...k continuity between each terminal shown below when the shift lever is moved to each position Shift position Terminal No to continuity P 6 9 1 3 R 2 3 N 6 9 3 5 D 3 7 2 3 4 L 3 8 OK There is continuity NG Replace the park neutral position switch OK Repair or replace harness or connector between battery and park neutral position switch park neutral position switch and ECM See page IN 30 905 ...

Page 907: ...emperature sensor S ECM P0712 ATF temperature sensor resistance is less than 79 Ω for 0 5 sec or more 1 trip detection logic P0713 DTC is detected for 0 5 sec or more 1 trip detection logic ATF temperature sensor resistance is more than 156 kΩ after started engine for 15 minutes or more MONITOR DESCRIPTION The automatic transmission fluid ATF temperature sensor converts ATF temperature to an elect...

Page 908: ...fication Minimum Maximum The monitor will run whenever these DTCs are not present See page DI 669 Range check Fluttering Low resistance The typical enabling condition is not avail able Range check High resistance Time after engine start 15 min or more TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Fluttering TFT transmission fluid temperature sensor resistance Less than 79...

Page 909: ...connector CHECK Measure resistance between terminals 1 and 6 of transmission wire connector OK 90 Ω to 156 kΩ HINT Refer to the table below for resistance values according to ATF temperature ATF temperature Specified condition 10 C 50 F 6 4 kΩ 25 C 77 F 3 5 kΩ 110 C 230 F 0 2 kΩ Measure resistance between terminals 1 and 6 of the transmis sion wire connector and body ground OK Resistance 1 MΩ or h...

Page 910: ...C TRANSAXLE U240E DI 709 2005 CELICA RM1131U 2 Check harness and connector between ATF temperature sensor and ECM See page IN 30 NG Repair or replace the harness or connector OK Check and replace the ECM See page IN 30 909 ...

Page 911: ...ould increase If the ATF temperature is below 10_C 50_F after running the vehicle for a certain period the ECM interprets this as a fault and turns on the MIL When the ATF temperature is 110_C 230_F or more after 17 minutes of engine cold start the ECM also determines this as a fault turns on the MIL and stores the DTC MONITOR STRATEGY Related DTCs P0711 ATF temperature sensor A Rationality check ...

Page 912: ...E 1 Check other DTCs output in addition to DTC P0711 PREPARATION a Warm up the engine b Turn the ignition switch off c Connect the OBD II scan tool or hand held tester to the DLC3 d Turn the ignition switch to the ON position e Push the ON button of the OBD II scan tool or the hand held tester f Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II s...

Page 913: ... DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U 2 Check transaxle fluid level See page DI 669 NG Add fluid See page DI 669 OK Replace the transmission wire ATF tempera ture sensor See page AX 6 912 ...

Page 914: ...ral position switch and ve hicle speed sensor are in normal operation S Open or short in input turbine NT speed sensor circuit S Input turbine NT speed sensor S ECM S Automatic transaxle assembly MONITOR DESCRIPTION The NT terminal of the ECM detects the revolving signal from speed sensor NT input RPM The ECM outputs a gearshift signal comparing the speed sensor NT with the speed sensor NC While t...

Page 915: ... page DI 669 Shift change Shift change is completed before starting next shift change operation ECM selected gear 2nd 3rd 4th or 5th Output shaft rpm 1 000 rpm or more NSW switch OFF R switch OFF L switch OFF Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Parameter Standard value Speed sensor NT Turbine speed...

Page 916: ...tween the sensor and transaxle case NG Tighten the speed sensor NT properly OK 2 Check speed sensor NT PREPARATION Remove the NT speed sensor from transaxle CHECK Measure resistance between terminals 1 and 2 of speed sen sor OK Resistance 620 60 Ω at 20 C 68 F NG Replace the speed sensor NT OK 3 Check harness and connector between ECM and speed sensor NT See page IN 30 NG Repair or replace harness...

Page 917: ...ult in the stop light switch and the MIL comes on and the ECM stores the DTC The vehicle must stop and go 3 km h 2 mph to 30 km h 19 mph 5 times for two driving cycles in order to detect malfunction MONITOR STRATEGY Related DTCs P0724 Stop light switch Range check Rationality Required sensors Components Main Stop light switch Required sensors Components Sub Vehicle speed sensor Frequency of operat...

Page 918: ...M See page DI 556 INSPECTION PROCEDURE 1 Check stop light switch See page BE 37 NG Replace stop light switch OK 2 Check harness and connector between ECM and stop light switch See page IN 30 NG Repair or replace harness or connector OK Check and replace the ECM See page IN 30 917 ...

Page 919: ...vehicle speed transmission temperature and gear selection The ECM determines the lock up status of the torque converter by comparing the engine rpm NE to the input turbine rpm NT The ECM calculates the actual transmission gear by comparing input turbine rpm NT to counter gear rpm NC When conditions are appropriate the ECM requests lock up by applying control voltage to shift solenoid DSL When the ...

Page 920: ...perature 60 C 140 F or more Transmission range D TFT transmission fluid temperature 20 C 4 F or more TFT sensor circuit Not circuit malfunction ECT sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit...

Page 921: ...cessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON Vehicle speed must be under 10 km h 6 2 mph once before 2nd detection INSPECTION PROCEDURE 1 Check solenoid valve DSL operation PREPARATION a Remove the oil pan b Remove the shift solenoid valve DSL CHECK a Applying 490 kPa 5 kgf cm2 71 psi of compressed air check that the solenoid valve does leak air b W...

Page 922: ... DIAGNOSTICS AUTOMATIC TRANSAXLE U240E DI 721 2005 CELICA RM1131U 2 Check valve body See page DI 698 NG Repair or replace the valve body OK Replace the torque converter clutch See page AX 30 921 ...

Page 923: ...t solenoid valve SL2 when DTC P0776 is output and check shift solenoid S4 when DTC P0766 is output MONITOR DESCRIPTION P0746 The ECM commands gear shifts by turning the shift solenoid valves ON OFF According to the input shaft revolution intermediate counter shaft revolution and output shaft revolution the ECM detects the actual gear position 1st 2nd 3rd or O D gear position When the gear position...

Page 924: ...766 Shift solenoid valve S4 ON malfunction Shift solenoid valve S4 OFF malfunction Required sensors Components Main Shift solenoid valve S4 Speed sensor NT Speed sensor NC Crank shaft position sensor NE Required sensors Components Sub ECT sensor ATF temperature sensor Throttle position sensor Vehicle speed sensor Frequency of operation Continuous Duration 1 sec MIL operation 2 driving cycles Seque...

Page 925: ...function ECM selected gear 1st Vehicle speed 10 to 40 km h 6 2 to 24 9 mph Throttle valve opening angle 4 5 or more at engine speed 1 900 rpm varies with engine speed ON malfunction A ECM selected gear 2nd Vehicle speed 10 km h 6 2 mph or more Throttle valve opening angle 4 5 or more at engine speed 1 900 rpm varies with engine speed ON malfunction B ECM lock up command OFF ECM selected gear 3rd o...

Page 926: ...sensor circuit Not circuit malfunction Turbine speed sensor circuit Not circuit malfunction Intermediate shaft speed sensor circuit Not circuit malfunction Output speed sensor circuit Not circuit malfunction Shift solenoid valve SL1 circuit Not circuit malfunction Shift solenoid valve SL2 circuit Not circuit malfunction Shift solenoid valve S4 circuit Not circuit malfunction Electronic throttle sy...

Page 927: ...rpm or more P0766 Detection criteria Threshold Either of the following conditions is met OFF malfunction or ON malfunction 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction Intermediate shaft speed Output speed 1 34 to 1 48 ON malfunction Intermediate shaft speed Output speed 0 95 to 1 09 P0776 Detection criteria Thresh...

Page 928: ...or b Shift solenoid valve S4 Measure resistance between terminal 1 of solenoid con nector and solenoid body Check Solenoid Operation a Shift solenoid valve SL1 or SL2 Connect the positive lead with an 23W bulb to terminal 1 and the negative lead to terminal 2 of solenoid con nector then check the movement of the valve b Shift solenoid valve S4 Connect the positive lead with an 23W bulb to terminal...

Page 929: ... Area P0748 P0778 The ECM checks for an open or short circuit in the shift sole noid valves SL1 and SL2 a When the solenoid is energized the duty ratio exceed 75 b When the solenoid is not energized the duty ratio is less than 3 S Open or short in shift solenoid valve SL1 SL2 circuit S Shift solenoid valve SL1 SL2 S ECM P0982 ECM detects short in solenoid valve No 2 circuit 2 times when solenoid v...

Page 930: ... ON OFF ON OFF ON OFF OFF OFF 3rd 3rd 3rd 3rd ON ON OFF ON OFF ON 2nd 2nd 2nd 2nd Solenoid Valve Gear X X X X Solenoid Valve Gear SHIFT SOLENOID SL1 SL2 AND S4 MALFUNCTIONING X X X X X X X X 3rd 3rd 3rd X X X X X X X X 3rd ON OFF OFF 3rd 3rd 3rd 3rd S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 S4 SL1 SL2 SHIFT SOLENOID SL2 AND S4 MALFUNCTIONING DIAGNOSTIC...

Page 931: ...solenoid valve SL2 Range check Required sensors Components P0748 Shift solenoid valve SL1 P0778 Shift solenoid valve SL2 Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None P0982 P0983 Related DTCs P0982 Shift solenoid valve S4 Range check Low resistance P0983 Shift solenoid valve S4 Range check High resistance Required sensors Components Shift solen...

Page 932: ...eck High resistance Shift solenoid valve OFF Battery voltage 8 V or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS P0748 P0778 Detection criteria Threshold Solenoid status from IC Fail Open or short P0982 P0983 Detection criteria Threshold Range check Low resistance Shift solenoid valve resistance 8 Ω or less Range check High resistance Shift solenoid valve resistance 100 kΩ or...

Page 933: ...O 5 10 4 9 8 Shift Solenoid Valve SL2 Shift Solenoid Valve S4 Shift Solenoid Valve SL1 E1 Automatic Transaxle E1 E1 E1 E1 E1 W B Y BR R Y 18 E11 E11 E11 E11 SL1 SL1 S2 SL2 S4 DI 732 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U WIRING DIAGRAM 932 ...

Page 934: ...n terminal SL1 and SL2 of transmission wire connector b Measure resistance between terminal SL2 and SL2 of transmission wire connector c Measure resistance between terminal S4 of transmission wire connector and body ground OK Resistance 5 0 to 5 6 Ω at 20 C 68 F CHECK Measure resistance between terminals SL1 SL1 SL2 and SL2 of the transmission wire connector and body ground OK Resistance 1 MΩ or h...

Page 935: ...ce between SL1 SL1 SL2 SL2 and S4 of ECM connector OK Resistance 5 0 to 5 6 Ω at 20 C 68 F CHECK Measure resistance between terminals SL1 SL1 SL2 and SL2 of the transmission wire connector and body ground OK Resistance 1 MΩ or higher NG Repair or replace the harness or connector See page IN 30 OK Check and replace the ECM See page IN 30 3 Check shift solenoid valve SL1 SL2 or S4 See page DI 722 NG...

Page 936: ...detects the revolving signal from speed sensor NC output rpm The ECM outputs a gearshift signal comparing the speed sensor NT with the speed sensor NC While the vehicle is operating in the 2nd 3rd or O D gear position in the shift position of D if the counter gear revolution is less than 300 rpm 1 although the output shaft revolution is more than 1 000 rpm 2 the ECM detects the trouble illuminates...

Page 937: ...CELICA RM1131U TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Parameter Standard value Counter gear speed sensor When shift position is D 3rd After warming up the engine S Output shaft speed becomes close to the input shaft speed WIRING DIAGRAM 936 ...

Page 938: ...tween the sensor and transaxle case NG Tighten the speed sensor NC properly OK 2 Check speed sensor NC PREPARATION Remove the NC speed sensor from transaxle CHECK Measure resistance between terminals 1 and 2 of speed sen sor OK Resistance 620 60 Ω at 20 C 68 F NG Replace the speed sensor NC OK 3 Check harness and connector between ECM and speed sensor NC See page IN 30 NG Repair or replace harness...

Page 939: ...his controls the line pressure and provides smooth shifting characteristics Upon receiving the throttle valve opening angle signal ECM controls the line pressure by sending a predetermined duty ratio to the solenoid valve modulating the line pressure gener ating throttle pressure Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle For example if A is the period of conti...

Page 940: ...lve SLT Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 669 Solenoid current cut status Not cut Battery voltage 11 V or more CPU command duty to SLT 19 or more Ignition switch ON Starter OFF TYPICAL MALFUNCTION THRESHOL...

Page 941: ...D13104 Shift Solenoid Valve SLT E1 2 E1 7 E10 17 E10 16 Y L Y G SLT SLT ECM O G SLT SLT E1 Automatic Transaxle DI 740 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U WIRING DIAGRAM 940 ...

Page 942: ...ove the oil pan c Disconnect the solenoid connector Check solenoid resistance CHECK Measure resistance between terminals 1 and 2 of solenoid con nector OK Resistance 5 0 to 5 6 Ω Check solenoid operation CHECK Connect positive lead with an 8 to 10W bulb to terminal 1 of solenoid connector and negative lead to terminal 2 then check the movement of the valve OK NG Replace shift solenoid valve SLT OK...

Page 943: ...cuit S Shift solenoid valve DSL S ECM Fail safe function If the ECM detects a malfunction it turns the shift solenoid valve DSL OFF MONITOR DESCRIPTION Based on the signals from the Throttle Position Sensor the Airflow Meter and the Crankshaft Position Sen sor the ECM sends a signal to the DSL Solenoid Valve to regulate the hydraulic pressure and provide smoother gearshifts The shift solenoid valv...

Page 944: ...ge DI 669 Range check Low resistance Solenoid current cut status Not cut Shift solenoid valve ON Battery voltage 8 V or more Ignition ON Starter OFF Range check High resistance Shift solenoid valve ON Battery voltage 8 V or more Ignition ON Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Range check Low resistance Shift solenoid valve resistance 8 Ω or less Range check High...

Page 945: ... body ground OK Resistance 11 to 15 Ω at 20 C 68 F NG Go to step 3 OK 2 Measure resistance between terminals DSL of ECM and body ground PREPARATION a Connect the transmission wire connector b Remove the ECM hood c Disconnect the connector from ECM CHECK Measure resistance between terminals DSL and E1 of ECM OK Resistance 11 to 15 Ω at 20 C 68 F NG Repair or replace the harness or connector See pag...

Page 946: ...DSL connector d Remove the shift solenoid valve DSL CHECK a Measure resistance between terminal DSL of shift sole noid valve and solenoid body b Connect positive lead to terminal of solenoid connec tor negative lead to solenoid body OK a Resistance 11 to 15 Ω b The shift solenoid valve DSL makes operation noise NG Replace the shift solenoid valve DSL OK Repair or replace the transmission wire See ...

Page 947: ... Panel J B Engine Room J B I10 Ignition SW DI 746 DIAGNOSTICS AUTOMATIC TRANSAXLE U240E 2005 CELICA RM1131U O D Main Switch O D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O D main switch is a momentary type switch When pressing the O D main switch the O D OFF indicator light lights up and ECM prohibits shifting to O D and when pressing it again the O D OFF indicator light goes off and ECM...

Page 948: ...lights up b O D OFF indicator light goes off OK Proceed to next inspection shown on problem symptoms tables See page DI 698 NG 2 Check and replace the combination meter See page BE 2 NG Replace the combination meter OK 3 Check O D main switch PREPARATION Disconnect the O D main switch connector CHECK Check continuity between terminals 5 and 6 of O D main switch connector OK O D main switch conditi...

Page 949: ...F OK O D main switch Specified voltage Press continuously O D main switch Continuity Release O D main switch No Continuity NG Repair or replace harness or connector See page IN 30 OK 5 Check voltage between terminal ODLP of ECM and body ground PREPARATION a Disconnect the connector of ECM b Turn the ignition switch ON CHECK Check voltage between terminal ODLP of ECM and body ground OK Voltage 9 to...

Page 950: ...DIAGNOSTICS AUTOMATIC TRANSAXLE U240E DI 749 2005 CELICA RM1131U Transmission Shift Switch Circuit CIRCUIT DESCRIPTION When shifting the shift lever to the M position using the transmission shift switch it is possible to shift to the 2 to 4 positions Pressing Up switch once shifts up 1 position and pressing Down switch once shifts down 1 position re spectively WIRING DIAGRAM DI25Z 13 949 ...

Page 951: ...itch pressed 3 6 No continuity Down switch released Continuity NG Replace the steering wheel OK 2 Check voltage between each of terminals SFTU and SFTD of ECM and body ground PREPARATION a Turn ignition switch ON b Remove the ECM with connectors still connected CHECK Check voltage between each terminal of SFTU and SFTD of ECM and body ground OK Switch condition Tester connection Specified conditio...

Page 952: ...DI 751 2005 CELICA RM1131U 3 Check harness and connector between ECM and transmission shift switch transmission shift switch and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page IN 30 951 ...

Page 953: ... CELICA RM1131U E Shift Main Switch Circuit CIRCUIT DESCRIPTION When the shift lever is shifted from the D to M position the E shift main switch is pressed M on the com bination meter lights up When the M on the combination meter turns off or when the M on the combina tion meter is flashing the system may be defective or the ATF temperature may be excessively high or low WIRING DIAGRAM DIAJ6 03 95...

Page 954: ...cator light is still flashing check if DTC P0710 P0712 or P0713 is displayed or not and inspect the transmission shift main switch circuit M position indicator light does not light up 1 Check E shift main switch PREPARATION Remove the E shift main switch CHECK Check continuity between each terminal of the E shift main switch OK Shift Lever Position Tester connection Specified value M 3 4 Continuit...

Page 955: ...U 3 Check harness and connector between body ECU and E shift main switch E shift main switch and combination meter See page IN 30 NG Repair or replace the harness or connector OK Proceed to next circuit inspection shown in problem symptoms table See page DI 698 954 ...

Page 956: ...es not occur symptom occurs Symptom Simulation DTC Chart Problem Symptom Confirmation Basic Inspection Mechanical System Test Manual Shifting Test NG OK Code NG OK NG NG NG NG OK Chapter 3 Off Vehicle End DTC Check OK OK OK Identification of Problem SO D Main Switch O D OFF Indicator Light Circuit SO D Cancel Signal Circuit Check Circuit Inspection Parts Inspection Repair Confirmation Test Chapter...

Page 957: ...E 2005 CELICA RM1131U PRECAUTION NOTICE Perform the RESET MEMORY AT initialization when replacing the automatic transaxle assy engine assy or the ECM See page DI 758 HINT Initialization can not be completed by only disconnecting the battery terminal 956 ...

Page 958: ...ove Any position Particular position No down shift O D 3rd 3rd 2nd 2nd 1st Lock up malfunction Shift point too high or too low Harsh engagement N D Lock up Any drive position Slip or shudder No kick down Others DTC Check 1st Time 2nd Time Check Item Normal code Malfunction code DTC Normal code Malfunction code DTC Malfunction Indicator Lamp Normal Remains ON How Often Does Problem Occur DIAGNOSTIC...

Page 959: ...ffect vehicle emissions In addition to the MIL lighting up when a malfunction is detected the applicable DTCs pre scribed by SAE J2012 are recorded in the ECM memory See page DI 42 If the malfunction does not occur in 3 consecutive trips the MIL goes off but the DTCs remain recorded in the ECM memory S To check the DTCs connect an OBD II scan tool or hand held tester to DLC3 on the vehicle The OBD...

Page 960: ...p b Inspect the DLC3 The vehicle s ECM uses ISO 9141 2 for communication The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141 2 format Tester connection Condition Specified condition 7 Bus ę Line 5 Signal ground During communication Pulse generation 4 Chassis Ground Body Always 1 Ω or less 5 Signal Ground Body Always 1 Ω or less 16 B Body Always 9 to 14 V HINT If your ...

Page 961: ...ote them down 1 Prepare an OBD II scan tool complying with SAE J1978 or hand held tester 2 Connect the OBD II scan tool or hand held tester to DLC3 at the lower of the instrument panel 3 Turn the ignition switch ON and turn the OBD II scan tool or hand held tester switch ON 4 Use the OBD II scan tool or hand held tester to check the DTCs and freeze frame data and note them down For operating instr...

Page 962: ... item DIAGNOSIS ENHANCED OBD II DTC INFO CLEAR CODES YES button HINT When operating the OBD II scan tool complying with SAE J1978 or hand held tester to erase the codes the DTCs and freeze frame data will be erased See the OBD II scan tool s instruction book for operating instructions d When not using the OBD II scan tool or hand held tester Clearing the DTCs Disconnect the battery terminal or rem...

Page 963: ... held tester 4 Connect the hand held tester to DLC3 at the lower side of the instrument panel 5 Turn the ignition switch ON and switch the hand held tester ON 6 Switch the hand held tester from Normal mode to Check mode Check that the MIL flashes 7 Start the engine MIL goes out after the engine starts 8 Simulate the conditions of the malfunction de scribed by the customer NOTICE Leave the ignition...

Page 964: ... item DIAGNOSIS ENHANCED OBD II DTC INFO CLEAR CODES YES button HINT When operating the OBD II scan tool complying with SAE J1978 or hand held tester to erase the codes the DTCs and freeze frame data will be erased See the OBD II scan tool s instruction book for operating instructions c When not using the OBD II scan tool or hand held tester Clearing the DTCs Disconnect the battery terminal or rem...

Page 965: ...er Position is S L 1st S 2 1st or 2nd S D O D OFF 1st 2nd or 3rd S D O D ON 1st 2nd 3rd or 4th O D LOCK UP SOL Lock Up Solenoid Status ON or OFF S Lock Up ON S Except Lock Up OFF PNP SW NSW PNP SW Status ON or OFF Ignition Key position is START ON Except START OFF LOW PNP SW Status ON or OFF Shift lever position is L ON Except L OFF The shift lever position and these values are different there are...

Page 966: ...e line pressure Vehicle Condition S Vehicle Stopped S IDL ON Others ON Line pressure up OFF No action normal operation 6 DEFINITION OF TERMS Monitor description Description of what the ECM monitors and how it detects malfunctions monitoring purpose and its details Related DTCs A group of diagnostic trouble codes that are output by the ECM based on the same malfunction detection logic Typical enabl...

Page 967: ... Vacuum sensor Manifold air pressure sensor Internal control module Control module Engine control ECU PCM Power train control module FC idle Deceleration fuel cut Idle air control valve Idle speed control VSV for CCV Canister close valve VSV for canister control Evaporative emissions canister vent valve VSV for EVAP Vacuum switching valve assembly No 1 EVAP VSV Purge VSV Evaporative emissions cani...

Page 968: ...fluid temperature sensor Electronic controlled automatic transmission ECT Electronically controlled automatic Intermediate shaft speed sensor A Counter gear speed sensor Output speed sensor Output shaft speed sensor Input speed sensor Input turbine speed sensor A Speed sensor NT Turbine speed sensor Input turbine speed sensor PNP switch NSW Park neutral position switch Pressure control solenoid Tr...

Page 969: ...r the following DTCs are not present Monitor Disablement List HINT This table indicates ECM monitoring status for the items in the upper columns if the DTCs in each line on the left are being set As for the X mark when the DTC on the left is stored detection of the DTC in the upper column is not per formed 968 ...

Page 970: ...A21571 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 769 2005 CELICA RM1131U 969 ...

Page 971: ...A21572 A22718 A22768 DI 770 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E 2005 CELICA RM1131U 970 ...

Page 972: ...A21573 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 771 2005 CELICA RM1131U 971 ...

Page 973: ...A21575 DI 772 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E 2005 CELICA RM1131U 972 ...

Page 974: ...A21576 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 773 2005 CELICA RM1131U Note 1 Without input speed sensor Note 2 With input speed sensor 973 ...

Page 975: ...ibration Drive in the D position lock up or O D gear and check for abnormal noises and vibration HINT The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be due to loss of balance in the differential torque converter clutch etc 4 Check kick down operation While driving in the D position 2nd 3rd and O D gears check that the possible kick down ve hi...

Page 976: ...le on a grade more than 5 and after shifting into the P position release the parking brake Then check that the parking lock pawl holds the vehicle in place 11 BASIC INSPECTION a Check the fluid level HINT S Drive the vehicle so that the engine and transaxle are at normal operating temperature Fluid temp 70 to 80 C 158 to 176 F S Only use the COOL range on the dipstick as a rough refer ence when th...

Page 977: ...ks in the transaxle If there are leaks it is necessary to repair or replace O rings gaskets oil seals plugs or other parts e Inspect and adjust the shift lever position When shifting the shift lever from the N position to other positions check that the lever can be shifted smoothly and accurately to each position and that the position indi cator is aligned with the correct position If the indicato...

Page 978: ...ear level area which provides good traction S The stall test should always be carried out in pairs One technician should observe the condi tions of wheels or wheel stoppers outside the vehicle while the other is doing the test 1 Chock the 4 wheels 2 Connect an OBD II scan tool or hand held tester to DLC3 3 Fully apply the parking brake 4 Keep your left foot pressed firmly on the brake pedal 5 Star...

Page 979: ...utch worn S 1st reverse brake worn 13 HYDRAULIC TEST Measure the line pressure NOTICE S Do the test at normal operation fluid temperature 50 to 80 C 122 to 176 F S The line pressure test should always be carried out in pairs One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test S Be careful to prevent SST s hose from interfer...

Page 980: ...ither mechanical or electrical factors Disconnecting the solenoid wire disables electrically controlled automatic gear shifting In this case operating the shift level is the only way to shift the transaxle gear If the gear is not changed by shift lever operation it is assumed that there is a mechanical problem a Turn the ignition switch OFF b Disconnect the solenoid wire connector c Warm up the en...

Page 981: ... characteristics Therefore when the automatic transaxle assy engine assy or ECM has been replaced it is necessary to reset the memory so that the ECM can memorize the new information Reset procedure is as follows a Turn the ignition switch off b Connect the hand held tester to the DLC3 c Turn the ignition switch to the ON position and push the hand held tester main switch on d Select the item DIAG...

Page 982: ... Torque Converter Clutch Sole noid Performance Shift Solenoid Valve SL S Shift solenoid valve SL is stuck open or closed S Valve body is blocked up or stuck S Lock up clutch S Automatic transaxle clutch brake or gear etc F f P0743 DI 809 Torque Converter Clutch Circuit Electrical Shift Solenoid Valve SL S Open or short in shift solenoid valve SL circuit S Shift solenoid valve SL S ECM F f P0751 DI...

Page 983: ... Valve ST Vehicle Speed Sensor ECM ATF Temperature Sensor Park Neutral Position Switch Input Turbine Speed Sensor NT Shift Solenoid Valve SL Shift Solenoid Valve SLT Shift Solenoid Valve No 1 Shift Solenoid Valve No 2 DI 782 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E 2005 CELICA RM1131U PARTS LOCATION 982 ...

Page 984: ...osition 10 14 V SLT E5 6 SLT E5 5 Y R Y G IG switch ON 10 14 V OD1 E3 1 E1 E4 17 B BR IG switch ON 5 6 V ODLP E3 19 E1 E4 17 BR Y BR O D main switch ON O D OFF Below 1 V O D main switch OFF O D ON 10 14 V L E4 9 E1 E4 17 Y B BR IG switch ON and Shift lever L position 10 14 V IG switch ON and Shift lever other than L position Below 1 V 2 E4 19 E1 E4 17 L Y BR IG switch ON and Shift lever 2 position...

Page 985: ...TRANSAXLE U341E 2005 CELICA RM1131U ODMS E2 5 E1 E4 17 BR Y BR IG switch ON 10 14 V IG switch ON and Press continuously O D main switch Below 1 V NT E5 16 NT E5 15 W L B Engine is running Pulse signal is output below 1 4 to 5 V 984 ...

Page 986: ...hest number in the table to continue the check If the trouble still occurs even though there are no abnormalities in any of the other circuits check and re place the ECM Chapter 1 Electronic Circuit Matrix Chart Symptom Suspected Area See page No up shift A particular gear from 1st to 3rd gear is not up shifted ECM No up shift 3rd O D 1 O D main switch and O D OFF indicator light circuit 2 O D can...

Page 987: ...oid relay valve 4 Solenoid modulator valve 5 Off vehicle repair matrix chart L L L L Harsh engagement N D 1 C1 accumulator 2 Accumulator control valve 3 Off vehicle repair matrix chart L L Harsh engagement N R 1 C3 accumulator 2 Accumulator control valve 3 Reverse control valve 4 Off vehicle repair matrix chart L L L Harsh engagement Lock up 1 Lock up relay valve 2 Accumulator control valve 3 Lock...

Page 988: ... DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 787 2005 CELICA RM1131U No kick down 1 1 2 shift valve 2 2 3 shift valve 3 3 4 shift valve L L L Poor acceleration SLT damper L 987 ...

Page 989: ...erse clutch 2 1st and reverse brake L L Harsh engagement Lock up Torque converter clutch AX 36 Harsh engagement 1st 2nd 1 2nd brake 2 One way clutch No 1 L L Harsh engagement 2nd 3rd Direct clutch L Harsh engagement 3rd O D O D and 2nd brake L Slip or shudder Forward position 1 Torque converter clutch 2 Forward clutch 3 Direct clutch 4 O D and 2nd brake 5 2nd brake 6 One way clutch No 1 7 One way ...

Page 990: ...e shift lever position and sends a signal to the ECM For security the park neutral position switch detects the shift lever position so that engine can be started only when the vehicle is in P or N shift position When the park neutral position switch sends more than one signal at a time from switch positions P R N or D the ECM interprets this as a fault in the switch The ECM will turn on the MIL an...

Page 991: ...LDS Detection criteria Threshold Number of the following signal input at the same time 2 or more P switch ON R switch N switch D switch 2 switch L switch COMPONENT OPERATING RANGE Parameter Standard value Park neutral position switch The park neutral switch sends only one signal to the ECM 990 ...

Page 992: ... Y B 1 AM1 IG1 Relay BK UP LP L Y P 5 8 4 NL LL 2L PL 3 RB DL RL 7 2 L W R B R L 2C 17 2C 6 2C 19 2C 18 2F 3 2F 22 2F 6 B O R B R L IB 7 6 C 3 5 2 1 IA 1 IK 5 IK 8 W 1 AM1 IG2 L R W B II 12 B R 2 1 Instrument Panel J B Engine Room J B Engine Room J B I10 Ignition SW DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 791 2005 CELICA RM1131U WIRING DIAGRAM 991 ...

Page 993: ...R B R AM2 ST2 I10 Ignition Switch 4 5 IE1 1 B W B W 1 1 1 2 ST RELAY W B EA1 14 B B 9 6 P1 Park Neutral Position Switch W B 4 EA1 B W IE4 1 B W IC1 3 6 W B IC1 W B A J3 J C IE Engine Room J B Engine Room J B DI 792 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E 2005 CELICA RM1131U 992 ...

Page 994: ... each terminal shown below when the shift lever is moved to each position Shift position Terminal No to continuity P 1 3 6 9 R 2 3 N 3 5 6 9 D 3 7 2 3 4 L 3 8 OK There is continuity NG Replace the park neutral position switch OK 2 Check harness and connector between ECM and park neutral position switch See page IN 30 NG Repair or replace the harness and connector OK Check and replace the ECM See p...

Page 995: ...e resistance value of the ATF temperature is less than 79 Ω 1 or more than 156 kΩ 2 the ECM interprets this as a fault in the ATF sensor or wiring The ECM will turn on the MIL and store the DTC 1 150_C 302_F or more is indicated regardless of the actual ATF temperature 2 40_C 40_F is indicated regardless of the actual ATF temperature HINT The ATF temperature can be checked on the OBD II scan tool ...

Page 996: ...LDS Detection criteria Threshold Range check Chattering TFT transmission fluid temperature sensor resistance Less than 79 Ω more than 156 kΩ Range check Low resistance TFT sensor resistance Less than 79 Ω Range check High resistance TFT sensor resistance More than 156 kΩ COMPONENT OPERATING RANGE Parameter Standard value TFT sensor Atmospheric temperature to approx 130 C 266 F WIRING DIAGRAM 995 ...

Page 997: ...low for resistance values according to ATF temperature ATF temperature Specified condition 10 C 50 F 6 4 kΩ 25 C 77 F 3 5 kΩ 110 C 230 F 0 2 kΩ Measure resistance between terminals 1 and 6 of the transmis sion wire connector and body ground OK Resistance 1 MΩ or higher NG Replace the ATF temperature sensor transmis sion wire OK 2 Check harness and connector between ATF temperature sensor and ECM S...

Page 998: ...o an electrical resistance value Based on the resistance the ECM determines the ATF temperature and detects an open or short in the ATF temperature circuit or a fault of the ATF temperature sensor After running the vehicle for a certain period the ATF temperature should increase If the ATF temperature is below 20_C 68_F after running the vehicle for a certain period the ECM interprets this as a fa...

Page 999: ...alfunction Time after engine start 16 min and 40 sec or more Duration time from TFT transmission fluid temperature Less than 20 C 68 F 3 sec or more ECT 15 C 5 F or more Time after engine start 18 min and 20 sec Driving distance after engine start 9 km 5 6 mile or more IAT 12 sec after engine start 10 C 14 F or more ECT 12 sec after engine start 10 C 14 F or more TYPICAL MALFUNCTION THRESHOLDS Det...

Page 1000: ... scan tool or the hand held tester f Select the item DIAGNOSIS ENHANCED OBD II DTC INFO CURRENT CODES CHECK Read the DTCs using the OBD II scan tool or the hand held tester RESULT Display DTC output Proceed to Only P0711 is output A P0711 and other DTCs B HINT If any other codes besides P0711 is output perform the troubleshooting for those DTCs first B Go to relevant DTC chart See page DI 781 A 2 ...

Page 1001: ...pm 300 rpm or less e T M output shaft rpm 1 000 rpm or more S Open or short in input turbine speed sensor NT circuit S Input turbine speed sensor NT S ECM MONITOR DESCRIPTION The NT terminal of the ECM detects the revolving signal from speed sensor NT input RPM The ECM outputs a gearshift signal comparing the speed sensor NT with the speed sensor NC While the vehicle is operating in the 2nd 3rd 4t...

Page 1002: ...ge DI 758 Shift change Shift change is completed and before starting next shift change operation ECM selected gear 2nd 3rd or 4th Output shaft rpm 1 000 rpm or more NSW switch OFF R switch OFF L switch OFF Engine Running TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Sensor signal rpm Less than 300 rpm COMPONENT OPERATING RANGE Parameter Standard value Speed sensor NT Turbine speed is...

Page 1003: ...ween the sensor and transaxle case NG Tighten the speed sensor NT properly OK 2 Check speed sensor NT PREPARATION Remove the NT speed sensor from transaxle CHECK Measure resistance between terminals 1 and 2 of speed sen sor OK Resistance 620 60 Ω at 20 C 68 F NG Replace the speed sensor NT OK 3 Check harness and connector between ECM and speed sensor NT See page IN 30 NG Repair or replace harness ...

Page 1004: ... this as a fault in the stop light switch and the MIL comes on and the ECM stores the DTC The vehicle must stop and go 3 km h 2 mph to 30 km h 19 mph 5 times for two driving cycles in order to detect malfunction MONITOR STRATEGY Related DTCs P0724 Stop light switch Range check Rationality Required sensors Components Main Stop light switch Required sensors Components Sub Vehicle speed sensor Freque...

Page 1005: ...U INSPECTION PROCEDURE 1 Check stop light switch See page BE 37 NG Replace stop light switch OK 2 Check harness and connector between ECM and stop light switch See page IN 30 NG Repair or replace harness or connector OK Check and replace the ECM See page IN 30 1004 ...

Page 1006: ...he ECM based on speed sensor NT speed sensor NC engine rpm engine load engine temperature vehicle speed transmission temperature and gear selection The ECM determines the lock up status of the torque converter by comparing the engine rpm NE to the input turbine rpm NT The ECM calculates the actual transmission gear by comparing input turbine rpm NT to counter gear rpm NC When conditions are approp...

Page 1007: ...uence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum All ECT Engine Coolant Temperature 60 C 140 F or more Vehicle speed 25 km h 15 5 mph or more Transmission range D ECM selected gear 3rd or 4th ECT sensor circuit Not circuit malfunction Shift solenoid valve S1 circuit Not circuit malfunction Shift solenoid valve S2 circuit Not circuit malfunction Shift solenoid ...

Page 1008: ...be under 10 km h 6 2 mph once before 2nd detection Difference between egine speed and Input turbine speed Less than 35 rpm INSPECTION PROCEDURE 1 Check solenoid valve SL operation PREPARATION a Remove the oil pan b Remove the solenoid valve SL CHECK a Applying 490 kPa 5 kgf cm2 71 psi of compressed air check that the solenoid valve does leak air b When battery voltage is supplied to the shift sole...

Page 1009: ...XLE U341E 2005 CELICA RM1131U 2 Check valve body See page DI 785 NG Repair or replace the valve body OK 3 Check the torque converter clutch See page AX 36 NG Repair the torque converter clutch OK Repair the transaxle See page AX 30 1008 ...

Page 1010: ...PTION Based on the signals from the Throttle Position Sensor the Airflow Meter and the Crankshaft Position Sen sor the ECM sends a signal to the SL Solenoid Valve to regulate the hydraulic pressure and provide smooth er gearshifts The shift solenoid valve SL responds to commands from the ECM The valve controls the look up relay valve to perform the torque converter lock up function If the ECM dete...

Page 1011: ...conditions is met Range check Low resistance or high resistance Low resistance Shift solenoid vavle SL resistance 8 Ω or less High resistance Shift solenoid vavle SL resistance 100 kΩ or more WIRING DIAGRAM INSPECTION PROCEDURE 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure resistance between SL of transmission wire and body ground OK Resistance 11 t...

Page 1012: ...tance 11 to 15 Ω at 20 C 68 F NG Repair or replace the harness or connector See page IN 30 OK Check and replace the ECM See page IN 30 3 Check shift solenoid valve SL PREPARATION a Jack up the vehicle b Remove the oil pan c Disconnect the shift solenoid valve SL connector d Remove the shift solenoid valve SL CHECK Measure resistance between terminal SL of shift solenoid valve and solenoid body OK ...

Page 1013: ...is output and check the shift solenoid valve No 2 when DTC P0756 is output MONITOR DESCRIPTION The ECM commands gear shifts by turning the shift solenoid valves ON OFF According to the input shaft revolution intermediate counter shaft revolution and output shaft revolution the ECM detects the actual gear position 1st 2nd 3rd or O D gear position When the gear position commanded by the ECM and the ...

Page 1014: ...S2 circuit Not circuit malfunction Input turbine speed sensor circuit Not circuit malfunction Internal counter shaft speed sensor circuit Not circuit malfunction Throttle sensor circuit Not circuit malfunction OFF malfunction A ECM selected gear 1st Vehicle speed 10 to 40 km h 6 2 to 24 9 mph Throttle valve opening angle 15 or more and 7 0 at engine speed 1 900 rpm varies with engine speed OFF mal...

Page 1015: ...es with engine speed OFF malfunction B ECM selected gear 3rd Vehicle speed 10 km h 6 2 mph or more Throttle valve opening angle 7 0 or more at engine speed 1 900rpm varies with engine speed OFF malfunction C ECM selected gear 4th Vehicle speed 10 km h 6 2 mph or more Throttle valve opening angle 7 0 or more at engine speed 1 900rpm varies with engine speed ON malfunction A ECM selected gear 2nd Ve...

Page 1016: ...t speed Output speed Not changed as follows 0 95 to 1 09 Last 0 64 to 0 78 Current ON malfunction B NE current NE last 1 100 rpm or more P0756 Detection criteria Threshold OFF malfunction All of the following conditions are met OFF malfunction A B and C 2 detections are necessary per driving cycle 1st detection temporary flag ON 2nd detection pending fault code ON OFF malfunction A Input speed Out...

Page 1017: ...2 CHECK a By applying 490 kPa 5 kgf cm2 71 psi of compressed air check that the solenoid valve does leak air b When battery voltage is supplied to the shift solenoid valve check that the valve closes OK a Solenoid valve does leak air b Solenoid valve closes NG Replace the shift solenoid valve No 1 or No 2 OK 2 Check the valve body See page DI 785 NG Repair or replace the valve body OK Repair or re...

Page 1018: ...id valve No 1 and No 2 controlled by ECM If an open or short circuit occurs in either of the solenoid valves the ECM controls the remaining normal solenoid valve to allow the vehicle to be operated smoothly Fail safe function HINT Check the sift solenoid valve No 1 when DTC P0753 is output and check the shift solenoid valve No 2 when DTC P0758 is output DTC No DTC Detecting Condition Trouble Area ...

Page 1019: ...ther shift solenoid valves in good condi tion ON OFF In case of an open or short circuit the ECM stops sending current to the circuit MONITOR STRATEGY Related DTCs P0753 Shift solenoid valve S1 Range check Low resistance Shift solenoid valve S1 Range check High resistance P0758 Shift solenoid valve S2 Range check Low resistance Shift solenoid valve S2 Range check High resistance Required sensors C...

Page 1020: ... B Y Y S1 S2 D12851 S1 S2 DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 819 2005 CELICA RM1131U WIRING DIAGRAM INSPECTION PROCEDURE 1 Check transmission wire PREPARATION Disconnect the transmission wire connector CHECK Measure resistance between S1 and S2 of transmission wire connector and body ground OK Resistance 11 to 15 Ω at 20 C 68 F NG Go to step 3 OK 1019 ...

Page 1021: ...d body ground OK Resistance 11 to 15 Ω at 20 C 68 F NG Repair or replace the harness or connector See page IN 30 OK Check and replace the ECM See page IN 30 3 Check shift solenoid valve No 1 or No 2 PREPARATION a Jack up the vehicle b Remove the oil pan c Disconnect the solenoid connector d Remove the shift solenoid valve No 1 or No 2 CHECK Measure resistance between solenoid connector and body gr...

Page 1022: ...olenoid valve ST S ECM MONITOR DESCRIPTION The ECM reduces the gear shift shock when shifting from the N position to the D position and from 3rd gear to 4th gear by regulating the hydraulic line pressure To regulate the pressure the ECM controls shift sole noid ST with a duty cycle signal that adjusts the line pressure If the ECM detects an open or short in the shift solenoid ST circuit it will il...

Page 1023: ...05 CELICA RM1131U TYPICAL MALFUNCTION THRESHOLDS Detection criteria Threshold Either of the following conditions is met Range check Low resistance or High resistance Range check Low resistance Shift solenoid valve resistance 8 Ω or less Range check High resistance Shift solenoid valve resistance 100 kΩ or less WIRING DIAGRAM 1022 ...

Page 1024: ...ground OK Resistance 11 to 15 Ω at 20 C 68 F NG Go to step 3 OK 2 Measure resistance between terminal ST of ECM and body ground PREPARATION a Connect the transmission wire connector b Remove the ECM hood c Disconnect the connector from ECM CHECK Measure resistance between terminal ST of ECM and body ground OK Resistance 11 to 15 Ω at 20 C 68 F NG Repair or replace the harness or connector See page...

Page 1025: ...sistance 11 to 15 Ω at 20 C 68 F b The solenoid makes an operating noise Mechanical check PREPARATION a Jack up the vehicle b Remove the oil pan c Disconnect the solenoid connector d Remove the shift solenoid valve ST CHECK a Applying 490 kPa 5 kgf cm2 71 psi of compressed air check that the solenoid valves do not leak air b When battery voltage is supplied to the shift solenoid valves check that ...

Page 1026: ...rols the line pressure and provides smooth shifting characteristics Upon receiving the throttle valve opening angle signal ECM controls the line pressure by sending a predetermined duty ratio to the solenoid valve modulating the line pressure gener ating throttle pressure Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle For example if A is the period of continuity in...

Page 1027: ...id valve SLT Frequency of operation Continuous Duration 1 sec MIL operation Immediate Sequence of operation None TYPICAL ENABLING CONDITIONS Item Specification Minimum Maximum The monitor will run whenever this DTC is not present See page DI 758 Solenoid current shout OFF Not cut Battery voltage 11 V or more CPU command duty ratio to SLT 19 or more Starter OFF TYPICAL MALFUNCTION THRESHOLDS Detect...

Page 1028: ...D13104 E5 SLT 6 Y R GR E5 SLT 5 ECM Y G Shift Solenoid Valve SLT G E1 3 E1 8 E1 Transaxle SLT SLT DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 827 2005 CELICA RM1131U WIRING DIAGRAM 1027 ...

Page 1029: ...nnector Check solenoid resistance CHECK Measure resistance between terminals 1 and 2 of solenoid con nector OK Resistance 5 0 to 5 6 Ω at 20 C 68 F Check solenoid operation CHECK Connect positive lead with an 5 to 6 W bulb to terminal 1 of solenoid connector and negative lead to terminal 2 then check the movement of the valve HINT The solenoid valve operates with the current of 0 9 1 0 A OK NG Rep...

Page 1030: ... Panel J B Engine Room J B I10 Ignition SW DIAGNOSTICS AUTOMATIC TRANSAXLE U341E DI 829 2005 CELICA RM1131U O D Main Switch O D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O D main switch is a momentary type switch When pressing the O D main switch the O D OFF indicator light lights up and ECM prohibits shifting to O D and when pressing it again the O D OFF indicator light goes off and ECM ...

Page 1031: ...lights up b O D OFF indicator light goes off OK Proceed to next inspection shown on problem symptoms tables See page DI 785 NG 2 Check and replace the combination meter See page BE 2 NG Replace the combination meter OK 3 Check O D main switch PREPARATION Disconnect the O D main switch connector CHECK Check continuity between terminals 5 and 6 of O D main switch connector OK O D main switch conditi...

Page 1032: ...OFF OK O D main switch Specified voltage Press continuously O D main switch Continuity Release O D main switch No Continuity NG Repair or replace harness or connector See page IN 30 OK 5 Check voltage between terminal ODLP of ECM and body ground PREPARATION a Disconnect the connector of ECM b Turn the ignition switch ON CHECK Check voltage between terminal ODLP of ECM and body ground OK Voltage 7 ...

Page 1033: ...DESCRIPTION While driving uphill with cruise control activated in order to minimize gear shifting and provide smooth cruis ing overdrive may be prohibited temporarily under some condition The cruise control ECU sends O D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued WIRING DIAGRAM DI4ZR 07 1032 ...

Page 1034: ...the ignition switch ON CHECK Measure voltage between terminal OD of cruise control ECU harness side connector and body ground OK Voltage 10 to 14 V OK Check and replace the cruise control ECU NG 2 Check voltage between terminal OD1 of ECM and body ground PREPARATION Turn the ignition switch ON CHECK Measure voltage between terminal OD1 of ECM and body ground OK Voltage 10 to 14 V OK Repair or repl...

Page 1035: ... of Problem Normal code Repair Confirmation Test End 1 2 3 4 5 6 7 8 9 10 11 Step 2 5 8 9 11 Diagnostic steps permitting the use of the TOYOTA hand held tester Fail safe function When a failure occurs in the ABS system the ABS warning light comes on and the ABS operation is prohibited In addition to this when the failure which disables the EBD operation occurs the brake warning light comes on as w...

Page 1036: ...day Remains ON Does not comes on DTC Check 1st Time 2nd Time Normal Code Malfunction Code Code Normal Code Malfunction Code Code Symptoms km miles ABS does not operate ABS Warning Light Abnormal ABS does not operate efficiently BRAKE Warning Light Abnormal Remains ON Does not come on DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD DI 835 2005 CELICA RM1131U CUSTOMER...

Page 1037: ... result is not normal proceed to trou bleshooting for the ABS warning light circuit or BRAKE warning light circuit See page DI 872 or DI 875 c In the case of not using TOYOTA hand held tester Check DTC 1 Using SST connect terminal Tc and CG of DLC3 SST 09843 18040 2 Turn the ignition switch to ON 3 Read DTC from the ABS warning light on the com bination meter HINT S If no code appears inspect the ...

Page 1038: ...r details e In case of not using TOYOTA hand held tester Clear the DTC 1 Using SST connect terminals Tc and CG of DLC3 SST 09843 18040 2 Turn the ignition switch to ON 3 Clear the DTC stored in ECU by depressing the brake pedal 8 times or more within 5 seconds 4 Check that the warning light shows the normal code 5 Remove the SST from the terminals of DLC3 SST 09843 18040 f In the case of using TOY...

Page 1039: ...on FR BE FORE or OPERATE BEFORE No ABS opera tion FR OPERATE During ABS operation FR ABS OPERT FL ABS operation FL BE FORE or OPERATE BEFORE No ABS opera tion FL OPERATE During ABS operation FL ABS OPERT RR ABS operation RR BE FORE or OPERATE BEFORE No ABS opera tion RR OPERATE During ABS operation RR ABS OPERT RL ABS operation RL BE FORE or OPERATE BEFORE No ABS opera tion RL OPERATE During ABS o...

Page 1040: ...horten the labor time It is possible to display the DATA LIST during the ACTIVE TEST a Connect the TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON c According to the display on tester perform the ACTIVE TEST Item Vehicle Condition Test Details Diagnostic Note SFRR Turns ABS solenoid SFRR ON OFF Operation of solenoid clicking sound can be heard SFRH Turns ABS solenoid SFRH ON OFF ...

Page 1041: ... at the occurrence of abnormality of the diagnosis code and during the ABS operation can be memorized and displayed using the TOYOTA hand held tester b Only one record of the freeze frame data is stored however the freeze frame data during the ABS operating is always up dated After the storage of the freeze frame data up to 31 ignition ON opera tions are stored and displayed HINT If the ignition s...

Page 1042: ...ld tester Check the speed sensor signal 1 Turn the ignition switch to OFF 2 Using SST connect terminal Ts and CG of DLC3 SST 09843 18040 3 Start the engine 4 Check that the ABS warning light blinks HINT If the ABS warning light does not blink inspect the ABS warning light circuit and the Ts circuit See page DI 872 and DI 879 5 Drive vehicle straight forward HINT Drive vehicle faster than 45 km h 2...

Page 1043: ... from ter minal Ts and CG Tc and CG of DLC3 and turn the ignition switch to OFF SST 09843 18040 b In case of using TOYOTA hand held tester Check DTC 1 Hook up the TOYOTA hand held tester to the DLC3 2 Do step 3 to 6 on the previous page 3 Read DTC by following the prompts on the tester screen HINT Please refer to the TOYOTA hand held tester operator s manu al for further details 1042 ...

Page 1044: ...it C0246 23 DI 855 Open or short circuit in 2 position solenoid circuit for right rear wheel S ABS actuator S SRRR or SRRH circuit C0256 24 DI 855 Open or short circuit in 2 position solenoid circuit for left rear wheel S ABS actuator S SRLR or SRLH circuit C0200 31 DI 848 Right front wheel speed sensor signal malfunction S Right front or left front speed sensor S Each speed sensor circuit S Speed...

Page 1045: ... left front speed sensor S Left front speed sensor S Sensor installation S Left front speed sensor rotor C1273 73 Low output voltage of right rear speed sensor S Right rear speed sensor S Sensor installation S Right rear speed sensor rotor C1274 74 Low output voltage of left rear speed sensor S Left rear speed sensor S Sensor installation S Left rear speed sensor rotor C1275 75 Abnormal change in ...

Page 1046: ...CU with Actuator Stop Light Switch DLC 3 Rear Speed Sensor Front Speed Sensor BRAKE Warning Light Parking Brake Switch Level Warning Switch Stop Light Bulb DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD DI 845 2005 CELICA RM1131U PARTS LOCATION 1045 ...

Page 1047: ...24 V W B IG switch ON ABS warning light ON 10 14 IG switch ON ABS warning light OFF Below 2 0 D G S11 14 GND1 2 S11 2 24 W W B IG switch ON 10 14 TS S11 15 GND1 2 S11 2 24 W R W B IG switch ON 10 14 TC S11 16 GND1 2 S11 2 24 P B W B IG switch ON 10 14 PKB S11 18 GND1 2 S11 2 24 R B W B IG switch ON parking switch ON Below 1 0 IG switch ON parking switch OFF 10 14 BM S11 23 GND1 2 S11 2 24 B R W B ...

Page 1048: ...ter If abnormal check the hydraulic circuit for leakage See page DI 881 DI 836 DI 863 DI 848 BR 48 ABS does not operate efficiently Only when 1 to 4 are all normal and the problem is still occurring replace the Skid Control ECU 1 Check the DTC reconfirming that the normal code is output 2 Speed sensor circuit 3 Stop light switch circuit 4 Check the ABS actuator with a TOYOTA hand held tester If ab...

Page 1049: ...hrough 3 1 Vehicle speed is at 10 km h 6 mph or more and the speed sensor signal circuit is open or short circuit con tinues for 15 sec or more 2 Momentary interruption of the speed sensor signal oc curs 7 times or more 3 Open circuit condition of the speed sensor signal circuit continues for 0 5 sec or more S Right front or left front speed sensor S Each speed sensor circuit S Speed sensor rotor ...

Page 1050: ...ear Speed Sensor 2 1 2 1 S11 W B 8 9 1 1 2 2 B W 31 30 11 12 33 34 IE3 IE3 IG3 IG3 2 6 7 II2 1 2 9 16 5 BR Y R G R G L P L L P P S11 S11 S11 S11 S11 S11 S11 II2 II2 II2 Skid Control ECU with Actuator DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD DI 849 2005 CELICA RM1131U WIRING DIAGRAM 1049 ...

Page 1051: ...ut from the speed sensor displayed on the TOYOTA hand held tester and the speed value displayed on the speedometer when driving the vehicle OK There is almost no difference between the two displayed speed values HINT There is tolerance of 10 in the speedometer indication OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG 2 Check speed sensor Front PREPARATION a Remove th...

Page 1052: ... ground OK Resistance 1 MΩ or higher Rear speed sensor sub wire harness PREPARATION a Remove the seat cushion and the seatback b Make sure that there is no looseness at the connector lock part and connecting part of the connector c Disconnect the speed sensor sub wire harness connec tor inside vehicle CHECK a Measure the resistance between terminal 1 of connector 1 and terminal 2 of connector 2 b ...

Page 1053: ...0 NG Repair or replace harness or connector OK 4 Check speed sensor installation CHECK Check the speed sensor installation OK Front The installation bolt is tightened properly and there is no clearance between the sensor and the steering knuckle Torque 8 0 N m 82 kgf cm 71 in lbf Rear There is no clearance between the sensor and the rear axle carrier NG Replace speed sensor NOTICE Check the speed ...

Page 1054: ... FR FR FL FL RR RR and RL RL of the Skid Control ECU harness side connector CHECK Drive the vehicle with about 30 km h 19 mph and check the signal waveform OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG 6 Check sensor rotor and sensor tip Front PREPARATION Remove the front drive shaft See page SA 21 CHECK Check the sensor rotor serrations OK No scratches or missing t...

Page 1055: ...HECK Check the sensor rotor serrations OK No scratches or missing teeth or foreign objects CHECK Check the sensor tip OK No scratches or foreign objects on the sensor tip NG Replace sensor rotor or speed sensor NOTICE Check the speed sensor signal again at the end of the pro cedure See page DI 836 OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 1054 ...

Page 1056: ... DTC No DTC Detection Condition Trouble Area C0226 21 C0236 22 1 When solenoid relay is ON and IG1 terminal voltage is 9 5 18 5 V solenoid circuit is open or short for 0 05 sec or longer 2 IG1 terminal voltage of skid control ECU is 9 5 18 5 V and while ABS is control in operation there is solenoid relay contact OFF for 0 05 sec or longer S ABS actuator S SFRR SFRH SFLR or SFLH circuit C0246 23 C0...

Page 1057: ...tion switch to ON and check that the same DTC is stored in the memory YES Replace ABS Actuator Assembly NO 2 Perform ACTIVE TEST by TOYOTA hand held tester a Select the item ABS SOLENOID RELAY in the ACTIVE TEST and operate the ABS solenoid relay on the TOYOTA hand held tester b Operat the ABS solenoid relay by the TOYOTA hand held tester CHECK Check that the same DTC is stored in the memeoty NO N...

Page 1058: ...ON and operates the ABS pump motor DTC No DTC Detection Condition Trouble Area C0273 13 S IG1 terminal voltage is from 9 5 V to 18 5 V and the relay contact OFF condition remains for 0 2 sec or more de spite turning the relay ON during the initial check or while ABS is in operation S IG1 terminal voltage decreases in 9 5 V or less and the relay contact OFF condition remains for 0 2 sec or more des...

Page 1059: ...Engine Room J B CHECK Check continuity of the ABS No 1 fuse OK Continuity NG Check for short circuit in all the harness and components connected to ABS No 1 fuse See attached wiring diagram OK 2 Check the DTC once more PREPARATION a Clear the DTC See page DI 836 b Turn the ignition switch to OFF CHECK Turn the ignition switch to ON and check that the same DTC is stored in the memory YES Replace AB...

Page 1060: ...ating it with the TOYOTA hand held tester OK The operation sound of the ABS motor should be heard NG Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 OK 4 Check voltage between terminals BM 23 and GND 2 24 of Skid Control ECU connector PREPARATION Disconnect the Skid Control ECU connector CHECK Measure the voltage between terminal 23 and 2 24 of the Skid Control ECU harness ...

Page 1061: ...er the ignition switch is turned ON and if the initial check is OK the relay turns on DTC No DTC Detection Condition Trouble Area C0278 11 S IG1 terminal voltage is from 9 5 V to 18 5 V and the relay contact OFF condition continues for 0 2 sec or more S IG1 terminal voltage decreases in 9 5 V or less because of the relay ON driving and the relay contact OFF condi tion elapses for 0 2 sec or more S...

Page 1062: ...m the Engine Room J B CHECK Check continuity of ABS No 2 fuse OK Continuity NG Check for short circuit in all the harness and components connected to ABS No 2 fuse See attached wiring diagram OK 2 Check the DTC once more PREPARATION a Clear DTC See page DI 836 b Turn the ignition switch to OFF CHECK Turn the ignition switch to ON and check that the same DTC is stored in the memory YES Replace ABS ...

Page 1063: ...relay when operating it with the TOYOTA hand held tester OK The operation sound of the ABS solenoid relay should be heard NG Check and replace ABS Actuator Assembly OK 4 Check voltage between terminals BS 1 and GND 2 24 of skid control ECU PREPARATION Disconnect the Skid Control ECU connector CHECK Measure the voltage between terminal 1 and 2 24 of the Skid Control ECU harness side connector OK Vo...

Page 1064: ...ELICA RM1131U DTC C1241 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source of ECU hence of CPU and of the ABS actuator DTC No DTC Detection Condition Trouble Area C1241 41 Condition 1 or 2 is detected 1 Vehicle speed is at 3 km h 1 9 mph or more and ECU terminal IG1 voltage is 9 5 V or less which continues for 10 sec or more 2 When IG terminal voltage is less than 9 5 V there ...

Page 1065: ...Check ABS IG fuse PREPARATION Remove the ABS IG fuse from Center J B CHECK Check continuity of the ABS IG fuse OK Continuity NG Check for short circuit in all the harness and components connected to ABS IG fuse See at tached wiring diagram OK 2 Check battery positive voltage OK Voltage 10 14 V NG Check and repair the charging system See page IN 30 OK 1064 ...

Page 1066: ...held tester CHECK OK Normal is displayed Voltage 10 14 V PREPARATION In the case of not using the hand held tester a Disconnect the Skid Control ECU connector b Turn the ignition switch to ON PREPARATION Measure the voltage between terminal 25 and 2 or 24 of the skid control ECU connector OK 10 14 V OK Check or replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG 4 Check continuity bet...

Page 1067: ...1 2 1 2 1 1 FL Main IK B R Skid Control ECU with Actuator G W 2 IE3 DI 866 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD 2005 CELICA RM1131U DTC C1249 49 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No DTC Detection Condition Trouble Area C1249 49 When IG1 terminal voltage is from 9 5 V to 18 5 V and ABS is not in operation the open circuit of the stop light ...

Page 1068: ... STP 10 of Skid Control ECU and body ground PREPARATION Disconnect Skid Control ECU connector CHECK Measure the voltage between terminal 10 of Skid Contorl ECU harness side connector and body ground when brake pedal is depressed OK Voltage 10 14 V OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG 3 Check for open circuit in harness and connector between Skid Control ECU...

Page 1069: ...B W B B R 2 1 2 1 2 DI 868 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD 2005 CELICA RM1131U DTC C1251 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area C1251 51 When the actuator pump drive motor does not rotate cor rectly ABS pump motor WIRING DIAGRAM DIAIM 04 1068 ...

Page 1070: ... the operation sound of the ABS pump motor when operating it with the TOYOTA hand held tester OK The operation sound of the ABS pump motor should be heard OK Proceed to next circuit inspection shown in problem symptoms chart See page DI 847 NG 2 Check continuity between terminals GND 2 24 of Skid Control ECU connector and body ground CHECK Measure the resistance between terminals 2 and 24 of Skid ...

Page 1071: ...ECU internal malfunction is detected 2 There is a malfunction in the ECU internal circuit S Battery S Charging system S Skid control ECU INSPECTION PROCEDURE 1 Is DTC output Check DTC on page DI 836 YES Repair circuit indicated by the code output NO 2 Is normal code displayed YES Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NO 3 Does ABS warning light go off YES Check an...

Page 1072: ...ning light PREPARATION a Disconnect the connector from the Skid Comtrol ECU b Connect the terminal WA S11 13 of the wire harness and the terminal GND S11 2 24 of the wire harness c Turn the ignition switch to ON CHECK Check the ABS warning light goes off OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG Check for short circuit in harness and connector between ABS warnin...

Page 1073: ...1 Skid Control ECU with Actuator V 4 IE3 DI 872 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD 2005 CELICA RM1131U ABS Warning Light Circuit CIRCUIT DESCRIPTION If ECU detects trouble it turns on the ABS warning light and prohibit the ABS control at the same time At this time the ECU records a DTC in memory Connect terminal TC and CG of the DLC3 to make the ABS war...

Page 1074: ...eld tester and start from step 5 in the case of not using TOYOTA hand held tester 1 Check operation of the ABS warning light PREPARATION a Connect the TOYOTA hand held tester to the DLC3 b Turn the ignition switch ON and push the TOYOTA hand held tester main switch ON c Select the ACTIVE TEST mode on the TOYOTA hand held tester CHECK Check that ON of the ABS warning light can be shown on the combi...

Page 1075: ...or open circuit in harness and connector between combination meter and ABS ECU See page IN 30 4 Check operation of the ABS warning light See step 1 OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 NG 5 Is DTC output Check DTC on page DI 836 YES Repair circuit indicated by the output code NO Check for short circuit in harness and connector between DLC3 and Skid Control ECU...

Page 1076: ...C13 Body ECU C13 3 8 IF R L B6 16 B6 2 1 EB R B2 Brake Fluid Level Warning Switch IE4 6 R B7 19 R B R B II2 5 S11 18 PKB P3 Parking Brake Switch R B PKB BLVL MPX1 1 2 W B GR IE3 14 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD DI 875 2005 CELICA RM1131U BRAKE Warning Light Circuit CIRCUIT DESCRIPTION The BRAKE warning light comes on when the brake fluid is insuffi...

Page 1077: ... OK 2 Check brake fluid level warning switch circuit See page BE 2 NG Repair or replace brake fluid level warning switch circuit OK 3 Is DTC output for ABS Check DTC on page DI 836 Yes Repair circuit indicated by the output code No 4 Check BRAKE warning light See combination meter troubleshooting on page BE 2 NG Repair or replace combination meter OK Check and replace Skid Control ECU ABS Actuator...

Page 1078: ...UTION EBD DI 877 2005 CELICA RM1131U TC Terminal Circuit CIRCUIT DESCRIPTION Connecting between terminal TC and CG of the DLC3 causes the ECU to display DTC by flashing the ABS warning light WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals TC and CG of DLC3 CHECK a Turn the ignition switch to ON b Measure the voltage between terminal TC and CG of DLC3 OK Voltage 10 14 V NG Go ...

Page 1079: ... DLC3 and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 3 Check ABS warning light a Using SST connect the terminal TC and CG of the DLC3 SST 09843 18040 b Turn the ignition switch to ON c Check the ABS warning light OK ABS warning light blinks OK END NG Check and replace Skid Control ECU ABS Actuato A...

Page 1080: ...ircuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the DTC check Connecting terminal TS and CG of the DLC3 starts the check WIRING DIAGRAM INSPECTION PROCEDURE 1 Check voltage between terminals TS and CG of DLC3 CHECK a Turn the ignition switch to ON b Measure the voltage between terminal TS and CG of DLC3 OK Voltage 1...

Page 1081: ... DLC3 and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace Skid Control ECU ABS Actuator Assembly See page IN 30 3 Check ABS warning light a Using SST connect the terminal TC and CG of the DLC3 SST 09843 18040 b Turn the ignition switch to ON c Check the ABS warning light OK ABS warning light blinks OK END NG Check and replace Skid Control ECU ABS Actuato A...

Page 1082: ...DIAGNOSTICS ANTI LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION EBD DI 881 2005 CELICA RM1131U Check for Fluid Leakage Check for fluid leakage from the actuator or the hydraulic lines DI6MR 05 1081 ...

Page 1083: ...ins OFF Clear DTC Present and Past DTC Items inside are titles of pages in this manual with the page number in the bottom portion See the pages for detailed explanations 1 2 4 3 5 7 8 9 10 DTC Chart 11 6 P DI 891 P IN 20 P DI 898 to DI 1033 Remains OFF Remains ON Vehicle Brought to Workshop Customer Problem Analysis DTC Check Read Present DTC Step 3 4 6 8 9 11 P DI 884 DTC Check Read Past DTC P DI...

Page 1084: ...iagnosis System Inspection SRS Warning Light Inspection DTC Inspection 1st Time 2nd Time 1st Time 2nd Time Inspector s Name Fine Cloudy Rainy Snowy Other Approx Starting Idling Driving Constant speed Acceleration Deceleration Other Remains ON Sometimes Lights Up Does Not Light Up Remains ON Sometimes Lights Up Does Not Light Up Normal Code Malfunction Code Normal Code Malfunction Code Code Code km...

Page 1085: ...a problem on the vehicle side or tool side S If communication is normal when the tool is connected to another vehicle inspect the DLC3 on the original vehicle S If communication is still not possible when the tool is con nected to another vehicle the problem is probably in the tool itself so consult the Service Department listed in the tool s instruction manual 2 SRS WARNING LIGHT CHECK a Turn the...

Page 1086: ...TICE Pay attention to the terminal connecting position to avoid a malfunction c Read the DTC Read the DTC by connecting the blinking times As an ex ample the blinking patterns of normal 11 and 31 are shown in the illustration S Normal code indication The light blinks 2 times per second S Malfunction code indication The first blinking indicates the first DTC Se cond blinking occurs after 1 5 second...

Page 1087: ...o the TOYOTA hand held tester operator s manu al for further details 5 DTC CLEARANCE Not using service wire When the ignition switch is turned off the diagnostic trouble code is cleared HINT Depending on the DTC the code might not be cleared by turn ing the ignition switch OFF In this case proceed to the next step 6 DTC CLEARANCE Using service wire a Connect the 2 service wires to terminal TC and ...

Page 1088: ...rounded HINT When alternately grounding terminal TC and AB release ground from one terminal and immediately ground the other ter minal within an interval of 0 2 seconds If DTCs are not cleared repeat the above procedure until the codes are cleared d Several seconds after doing the clearing procedure the SRS warning light will blink in a 50 m sec cycle to indi cate the codes which have been cleared...

Page 1089: ... with the same thickness as the male terminal between the terminal and the short spring to release it Refer to illustrations on next 2 pages CAUTION Never release the airbag activation prevention mechanism on the squib connector NOTICE S Do not release the airbag activation prevention mech anism unless specifically directed by the trouble shooting procedure S To prevent the terminal and the short ...

Page 1090: ...tensioner RH Side Airbag Sensor Assembly RH Front Airbag Sensor RH Front Passenger Airbag Assembly Squib Spiral Cable Steering Wheel Pad Squib Front Airbag Sensor LH Side Airbag Sensor Assembly LH Seat Belt Pretensioner LH Side Airbag Assembly LH Squib Door Side Airbag Sensor LH DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 889 2005 CELICA RM1131U 1089 ...

Page 1091: ...embly Connector Short Spring Short Spring Short Spring Before Release After Release Connector Connector Short Spring Short Spring Before Release Paper After Release Paper 4 8 19 5 Paper 2 1 3 6 DI 890 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM 2005 CELICA RM1131U 1090 ...

Page 1092: ...ument panel wire ON B0106 54 DI 919 S Open in P squib circuit S Front passenger airbag assembly squib S Airbag sensor assembly S Instrument panel wire ON B0107 51 DI 922 S Short in P squib circuit to ground S Front passenger airbag assembly squib S Airbag sensor assembly S Instrument panel wire ON B0108 52 DI 925 S Short in P squib circuit to B S Front passenger airbag assembly squib S Airbag sens...

Page 1093: ...36 74 DI 971 S Open in P T squib LH circuit S Seat belt pretensioner LH squib S Airbag sensor assembly S Floor wire Blink B0137 71 DI 974 S Short in P T squib LH circuit to ground S Seat belt pretensioner LH squib S Airbag sensor assembly S Floor wire Blink B0138 72 DI 977 S Short in P T squib LH circuit to B S Seat belt pretensioner LH squib S Airbag sensor assembly S Floor wire Blink B1100 31 DI...

Page 1094: ...a voltage source drop is possible This malfunction is not stored in memory by the airbag sensor assembly and if the power source volt age returns to normal the SRS warning light will automatically go out S When 2 or more codes are indicated smaller numbered code will be shown first S If a code not listed on the chart is displayed the airbag sensor assembly is at fault S In the case of any malfunct...

Page 1095: ...bag Assembly Combination Meter Warning Light Front Airbag Sensor LH Front Airbag Sensor RH Seat Belt Pretensioner RH Seat Belt Pretensioner LH Side Airbag Sensor Assembly LH Airbag Sensor Assembly Door Side Airbag Sensor LH Side Airbag Assembly LH Spiral Cable DI 894 DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM 2005 CELICA RM1131U PARTS LOCATION 1094 ...

Page 1096: ...Power Source C6 6 IG1 Power Source C6 7 DMR Door Side Airbag Sensor RH C6 8 DMR Door Side Airbag Sensor RH C6 9 SR Front Airbag Sensor RH C6 10 P Squib Passenger C6 11 P Squib Passenger C6 12 SIL Diagnosis C6 13 D Squib Driver C6 14 D Squib Driver C6 15 SL Front Airbag Sensor LH C6 16 DML Door Side Airbag Sensor LH C6 17 DML Door Side Airbag Sensor LH C6 19 TC Diagnosis C6 20 SR Front Airbag Senso...

Page 1097: ...Assembly LH C7 10 FSL Side Airbag Sensor Assembly LH C7 11 LBE Body ECU C7 12 ESL Side Airbag Sensor Assembly LH C8 1 SFR Squib Side RH C8 2 SFR Squib Side RH C8 5 PR Squib Pretensioner RH C8 6 PR Squib Pretensioner RH C8 7 ESR Side Airbag Sensor Assembly RH C8 9 FSR Side Airbag Sensor Assembly RH C8 10 SSR Side Airbag Sensor Assembly RH C8 12 VUPR Side Airbag Sensor Assembly RH 1096 ...

Page 1098: ...light sometimes lights up after approx 6 seconds have elapsed S SRS warning light circuit DI 1028 S SRS warning light is always lit up even when ignition switch is in the LOCK position S With the ignition switch in ON position the SRS warning light does not light up S DTC is not displayed S TC terminal circuit DI 1033 S SRS warning light is always lit up at the time of DTC check pro cedure S DTC i...

Page 1099: ...ing wheel pad It causes the airbag to deploy when the airbag deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0100 13 is recorded when a short is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0100 13 S Short in D squib wire harness S D squib malfunction S Spiral cable malfunction S Airbag sensor assembl...

Page 1100: ... wire harness PREPARATION Release the airbag activation prevention mechanism built in the connector on the airbag sensor assembly side between the steering wheel pad D squib and the airbag sensor assembly See page DI 884 CHECK Measure the resistance between D and D on the steering wheel pad D squib side between the airbag sensor assembly and the steering wheel pad D squib OK Resistance 1 MΩ or Hig...

Page 1101: ... to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0100 13 is not output HINT Codes other than code B0100 ...

Page 1102: ...d wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0100 13 is not output HINT Codes other than code B0100 13 may be output a...

Page 1103: ...CHECK Measure the resistance between D and D of the spiral cable connector on the steering wheel pad D squib side OK Resistance 1 MΩ or Higher NG Replace spiral cable OK 6 Check instrument panel wire PREPARATION Release the airbag activation prevention mechanism built in the instrument panel wire connector on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between D an...

Page 1104: ... is recorded when an open is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0101 14 S Open in D squib wire harness S D squib malfunction S Spiral cable malfunction S Airbag sensor assembly malfunction S Steering wheel pad D squib S Spiral cable S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 898 INSPECTION PROCEDURE 1 Prepare for inspection...

Page 1105: ...s sembly and the steering wheel pad D squib c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DT...

Page 1106: ...d wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0101 14 is not output HINT Codes other than code B0101 14 may be output a...

Page 1107: ...t pan el wire CHECK Measure the resistance between D and D of the spiral cable connector on the steering wheel pad D squib side OK Resistance Below 1 Ω NG Replace spiral cable OK 6 Check instrument panel wire CHECK Measure the resistance between D and D of the instrument panel wire connector on the spiral cable side OK Resistance Below 1 Ω NG Repair or replace instrument panel wire OK From the res...

Page 1108: ... a ground short is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0102 11 S Short in D squib wire harness to ground S D squib malfunction S Spiral cable malfunction S Airbag sensor assembly malfunction S Steering wheel pad D squib S Spiral cable S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 898 INSPECTION PROCEDURE 1 Prepare for inspectio...

Page 1109: ...s sembly and the steering wheel pad D squib c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DT...

Page 1110: ... ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0102 11 is not output HINT Codes other than code B0102 11 may be output at this time but they are not relevant to this check NG Replace st...

Page 1111: ...al cable connector on the steering wheel pad D squib side OK Resistance 1 MΩ or Higher NG Replace spiral cable OK 6 Check instrument panel wire CHECK Measure the resistance between the body ground and D of the instrument panel wire connector on the spiral cable side OK Resistance 1 MΩ or Higher NG Repair or replace instrument panel wire OK From the results of the above inspection the malfunctionin...

Page 1112: ... short is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0103 12 S Short in D squib wire harness to B S D squib malfunction S Spiral cable malfunction S Airbag sensor assembly malfunction S Steering wheel pad D squib S Spiral cable S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 898 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 o...

Page 1113: ...s sembly and the steering wheel pad D squib c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DT...

Page 1114: ...to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0103 12 is not output HINT Codes other than code B0103 12 may be output at this time but they are not relevant to this check NG Replace ...

Page 1115: ...en the body ground and D of the spiral cable connector on the steering wheel pad D squib side OK Voltage Below 1 V NG Replace spiral cable OK 6 Check instrument panel wire CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and D of the instrument panel wire connector on the spiral cable side OK Voltage Below 1 V NG Repair or replace instrument panel wire OK From t...

Page 1116: ...embly It causes the SRS to deploy when the SRS deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0105 53 is recorded when a short is detected in the P squib circuit DTC No DTC Detecting Condition Trouble Area B0105 53 S Short in P squib wire harness S P squib malfunction S Airbag sensor assembly malfunction S Front passenger airbag as...

Page 1117: ... DI 1025 2 Check instrument panel wire PREPARATION Release the airbag activation prevention mechanism built in the instrument panel wire connector on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between P and P of the instrument panel wire connector on the front passenger airbag assembly P squib side OK Resistance 1 MΩ or Higher NG Repair or replace instrument panel...

Page 1118: ... battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0105 53 is not output HINT Codes other than code B0105 53 may ...

Page 1119: ...east for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0105 53 is not output HINT Codes other than code B0105 53 may be output at this time...

Page 1120: ... B0106 54 is recorded when an open is detected in the P squib circuit DTC No DTC Detecting Condition Trouble Area B0106 54 S Open in P squib wire harness S P squib malfunction S Airbag sensor assembly malfunction S Front passenger airbag assembly P squib S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 915 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 on page ...

Page 1121: ...assenger airbag as sembly P squib side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See...

Page 1122: ...east for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0106 54 is not output HINT Codes other than code B0106 54 may be output at this time...

Page 1123: ...recorded when ground short is detected in the P squib circuit DTC No DTC Detecting Condition Trouble Area B0107 51 S Short in P squib wire harness to ground S P squib malfunction S Airbag sensor assembly malfunction S Front passenger airbag assembly P squib S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 915 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 on pa...

Page 1124: ...ssenger airbag as sembly P squib side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See ...

Page 1125: ...ait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0107 51 is not output HINT Codes other than code B0107 51 may be output at this time but they are not relevant to this check NG Replace front passe...

Page 1126: ...ed when a B short is detected in the P squib circuit DTC No DTC Detecting Condition Trouble Area B0108 52 S Short in P squib wire harness to B S P squib malfunction S Airbag sensor assembly malfunction S Front passenger airbag assembly P squib S Airbag sensor assembly S Instrument panel wire WIRING DIAGRAM See page DI 915 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 on page DI 1025 2 C...

Page 1127: ...ssenger airbag as sembly P squib side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See ...

Page 1128: ...ait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0108 52 is not output HINT Codes other than code B0108 52 may be output at this time but they are not relevant to this check NG Replace front passe...

Page 1129: ...airbag assembly RH It causes the SRS to deploy when the SRS deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0110 43 is recorded when a short is detected in the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0110 43 S Short in side squib RH wire harness S Side squib RH malfunction S Airbag sensor assembly malfunct...

Page 1130: ...ee step 1 on page DI 1025 2 Check floor wire PREPARATION Release the airbag activation prevention mechanism built in the connector of the floor wire on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between SFR and SFR of the floor wire connector on the side airbag assembly RH side squib RH side OK Resistance 1 MΩ or Higher NG Repair or replace floor wire OK 1129 ...

Page 1131: ...the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch or ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0110 43 is not output HINT Codes other than code B0110 43 m...

Page 1132: ...t at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0110 43 is not output HINT Codes other than code B0110 43 may be output at thi...

Page 1133: ...n page RS 2 DTC B0111 44 is recorded when an open is detected in the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0111 44 S Open in side squib RH wire harness S Side squib RH malfunction S Airbag sensor assembly malfunction S Side airbag assembly RH Side squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 928 INSPECTION PROCEDURE 1 Prepare for inspection...

Page 1134: ...g assembly RH side squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page ...

Page 1135: ...t at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0111 44 is not output HINT Codes other than code B0111 44 may be output at thi...

Page 1136: ...C B0112 41 is recorded when ground short is detected in the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0112 41 S Short in side squib RH wire harness to ground S Side squib RH malfunction S Airbag sensor assembly malfunction S Side airbag assembly RH Side squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 928 INSPECTION PROCEDURE 1 Prepare for inspecti...

Page 1137: ...g assembly RH side squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page ...

Page 1138: ... and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0112 41 is not output HINT Codes other than code B0112 41 may be output at this time but they are not relevant to this check NG Replace side ...

Page 1139: ...113 42 is recorded when a B short is detected in the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0113 42 S Short in side squib RH wire harness to B S Side squib RH malfunction S Airbag sensor assembly malfunction S Side airbag assembly RH Side squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 928 INSPECTION PROCEDURE 1 Prepare for inspection See step ...

Page 1140: ...g assembly RH side squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page ...

Page 1141: ... and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0113 42 is not output HINT Codes other than code B0113 42 may be output at this time but they are not relevant to this check NG Replace side ...

Page 1142: ...airbag assembly LH It causes the SRS to deploy when the SRS deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0115 47 is recorded when a short is detected in the side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0115 47 S Short in side squib LH wire harness S Side squib LH malfunction S Airbag sensor assembly malfunct...

Page 1143: ...ee step 1 on page DI 1025 2 Check floor wire PREPARATION Release the airbag activation prevention mechanism built in the connector of the floor wire on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between SFL and SFL of the floor wire connector on the side airbag assembly LH side squib LH side OK Resistance 1 MΩ or Higher NG Repair or replace floor wire OK 1142 ...

Page 1144: ...the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0115 47 is not output HINT Codes other than code B0115 47 m...

Page 1145: ...ast for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0115 47 is not output HINT Codes other than code B0115 47 may be output at this time ...

Page 1146: ...n page RS 2 DTC B0116 48 is recorded when an open is detected in the side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0116 48 S Open in side squib LH wire harness S Side squib LH malfunction S Airbag sensor assembly malfunction S Side airbag assembly LH Side squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 941 INSPECTION PROCEDURE 1 Prepare for inspection...

Page 1147: ...bag assembly LH side squib LH side c Connect the negative terminal cable to the battery and wait at least 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1148: ...t at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0116 48 is not output HINT Codes other than code B0116 48 may be output at thi...

Page 1149: ...TC B0117 45 is recorded when ground short is detected in the side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0117 45 S Short in side squib LH wire harness to ground S Side squib LH malfunction S Airbag sensor assembly malfunction S Side airbag assembly LH Side squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 941 INSPECTION PROCEDURE 1 Prepare for inspect...

Page 1150: ...g assembly LH side squib LH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page ...

Page 1151: ... and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0117 45 is not output HINT Codes other than code B0117 45 may be output at this time but they are not relevant to this check NG Replace side ...

Page 1152: ...18 46 is recorded when a B short is detected in the side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0118 46 S Short in side squib LH wire harness to B S Side squib LH malfunction S Airbag sensor assembly malfunction S Side airbag assembly LH Side squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 941 INSPECTION PROCEDURE 1 Prepare for inspection See step 1...

Page 1153: ...g assembly LH side squib LH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page ...

Page 1154: ... and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0118 46 is not output HINT Codes other than code B0118 46 may be output at this time but they are not relevant to this check NG Replace side ...

Page 1155: ...oner RH It causes the SRS to deploy when the SRS deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0130 63 is recorded when a short is detected in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0130 63 S Short in P T squib RH wire harness S P T squib RH malfunction S Airbag sensor assembly malfunction S Seat bel...

Page 1156: ...e step 1 on page DI 1025 2 Check floor wire PREPARATION Release the airbag activation prevention mechanism built in the connector of the floor wire on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between PR and PR of the floor wire connector on the seat belt pretensioner RH P T squib RH side OK Resistance 1 MΩ or Higher NG Repair or replace floor wire OK 1155 ...

Page 1157: ...the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0130 63 is not output HINT Codes other than code B0130 63 m...

Page 1158: ... at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0130 63 is not output HINT Codes other than code B0130 63 may be output at this...

Page 1159: ...n page RS 2 DTC B0131 64 is recorded when an open is detected in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0131 64 S Open in P T squib RH wire harness S P T squib RH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner RH P T squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 954 INSPECTION PROCEDURE 1 Prepare for inspection S...

Page 1160: ...tensioner RH P T squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1161: ... at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0131 64 is not output HINT Codes other than code B0131 64 may be output at this...

Page 1162: ...C B0132 61 is recorded when a ground short is detected in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0132 61 S Short in P T squib RH wire harness to ground S P T squib RH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner RH P T squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 954 INSPECTION PROCEDURE 1 Prepare for inspecti...

Page 1163: ...pretensioner RH P T squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page...

Page 1164: ...and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0132 61 is not output HINT Codes other than code B0132 61 may be output at this time but they are not relevant to this check NG Replace seat b...

Page 1165: ...33 62 is recorded when a B short is detected in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0133 62 S Short in P T squib RH wire harness to B S P T squib RH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner RH P T squib RH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 954 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 o...

Page 1166: ...tensioner RH P T squib RH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1167: ...d wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0133 62 is not output HINT Codes other than code B0133 62 may be output at this time but they are not relevant to this check NG Replace seat bel...

Page 1168: ...ner LH It causes the SRS to deploy when the SRS deployment conditions are satisfied For details of the function of each component see OPERATION on page RS 2 DTC B0135 73 is recorded when a short is detected in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0135 73 S Short in P T squib LH wire harness S P T squib LH malfunction S Airbag sensor assembly malfunction S Seat belt...

Page 1169: ...e step 1 on page DI 1025 2 Check floor wire PREPARATION Release the airbag activation prevention mechanism built in the connector of the floor wire on the airbag sensor assembly side See page DI 884 CHECK Measure the resistance between PL and PL of the floor wire connector on the seat belt pretensioner LH P T squib LH side OK Resistance 1 MΩ or Higher NG Repair or replace floor wire OK 1168 ...

Page 1170: ...the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0135 73 is not output HINT Codes other than code B0135 73 m...

Page 1171: ... at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0135 73 is not output HINT Codes other than code B0135 73 may be output at this...

Page 1172: ...n page RS 2 DTC B0136 74 is recorded when an open is detected in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0136 74 S Open in P T squib LH wire harness S P T squib LH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner LH P T squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 967 INSPECTION PROCEDURE 1 Prepare for inspection S...

Page 1173: ...tensioner LH P T squib LH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1174: ... at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0136 74 is not output HINT Codes other than code B0136 74 may be output at this...

Page 1175: ...C B0137 71 is recorded when a ground short is detected in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0137 71 S Short in P T squib LH wire harness to ground S P T squib LH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner LH P T squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 967 INSPECTION PROCEDURE 1 Prepare for inspecti...

Page 1176: ...tensioner LH P T squib LH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1177: ...ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0137 71 is not output HINT Codes other than code B0137 71 may be output at this time but they are not relevant to this check NG Replace sea...

Page 1178: ...38 72 is recorded when a B short is detected in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0138 72 S Short in P T squib LH wire harness to B S P T squib LH malfunction S Airbag sensor assembly malfunction S Seat belt pretensioner LH P T squib LH S Airbag sensor assembly S Floor wire WIRING DIAGRAM See page DI 967 INSPECTION PROCEDURE 1 Prepare for inspection See step 1 o...

Page 1179: ...tensioner LH P T squib LH side c Connect the negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI...

Page 1180: ...and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B0138 72 is not output HINT Codes other than code B0138 72 may be output at this time but they are not relevant to this check NG Replace seat b...

Page 1181: ... airbag sensor assembly is detected DTC No DTC Detecting Condition Trouble Area B1100 31 S Airbag sensor assembly malfunction S Airbag sensor assembly INSPECTION PROCEDURE HINT When a malfunction code other than code B1100 31 is displayed at the same time first repair the malfunction indicated by the malfunction code other than code B1100 31 1 Prepare for inspection See step 1 on page DI 1025 2 Ch...

Page 1182: ...o LOCK and wait at least for 10 seconds b Turn the ignition switch to ON and wait at least for 10 se conds c Repeat operation in step a and b at least 5 times d Check the DTC See page DI 884 OK DTC B1100 31 is output HINT Codes other than code B1100 31 may be output at this time but they are not relevant to this check NO Using simulation method reproduce malfunc tion symptoms See page IN 20 YES Re...

Page 1183: ...sists of the safing sensor diagnosis circuit and lateral deceleration sensor etc It receives signals from the lateral deceleration sensor judges whether or not the SRS must be activated and detects diagnosis system malfunction DTC B1140 32 is recorded when occurrence of a malfunction in the side airbag sensor assembly RH is de tected DTC No DTC Detecting Condition Trouble Area B1140 32 S Side airb...

Page 1184: ...OCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1140 32 is output HINT Codes other than code B1140 32 may be output at this time but they are not relevant to this check NO The malfunctioning part can now be considered normal To make sure of this use the simulation method to check YES 2 Is connector of s...

Page 1185: ...NTAL RESTRAINT SYSTEM 2005 CELICA RM1131U 4 Check floor wire PREPARATION Using a service wire connect SSR and ESR of the floor wire connector on the side airbag sensor assembly RH side CHECK Measure the resistance between SSR and ESR of the floor wire connector on the airbag sensor assembly side OK Resistance Below 1 Ω NG Repair or replace floor wire OK 1184 ...

Page 1186: ...M DI 985 2005 CELICA RM1131U 5 Check floor wire PREPARATION Measure the resistance between VUPR and FSR of the floor wire connector on the airbag sensor assembly side CHECK Measure the resistance between the body ground and each of SSR VUPR and FSR of the floor wire connector on the airbag sensor assembly side OK Resistance Below 1 Ω NG Repair or replace floor wire OK 1185 ...

Page 1187: ...LICA RM1131U 6 Check floor wire to ground CHECK Measure the resistance between the body ground and each of SSR VUPR and FSR of the floor wire connector on the airbag sensor assembly side OK Resistance 1M Ω or Higher NG Repair or replace floor wire OK 7 Check floor wire to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and each of VUPR SSR FSR and ESR of the ...

Page 1188: ...at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK Neither DTC B1140 32 nor B1141 33 are not output HINT Codes other than code B1140 32 ...

Page 1189: ...onsists of the safing sensor diagnosis circuit and lateral deceleration sensor etc It receives signals from the lateral deceleration sensor judges whether or not the SRS must be activated and detects diagnosis system malfunction DTC B1141 33 is recorded when occurrence of a malfunction in the side airbag sensor assembly LH is de tected DTC No DTC Detecting Condition Trouble Area B1141 33 S Side ai...

Page 1190: ... and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1141 33 is output HINT Codes other than code B1141 33 may be output at this time but they are not relevant to this check NO The malfunctioning part can now be considered normal To make sure of this use the simulation method to check YES 2 Is connector of side...

Page 1191: ...NTAL RESTRAINT SYSTEM 2005 CELICA RM1131U 4 Check floor wire PREPARATION Using a service wire connect SSL and ESL of the floor wire connector on the side airbag sensor assembly LH side CHECK Measure the resistance between SSL and ESL of the floor wire connector on the airbag sensor assembly side OK Resistance Below 1 Ω NG Repair or replace floor wire OK 1190 ...

Page 1192: ...STRAINT SYSTEM DI 991 2005 CELICA RM1131U 5 Check floor wire PREPARATION Using a service wire connect VUPL and FSL of the floor wire connector on the side airbag sensor assembly LH side CHECK Measure the resistance between VUPL and FSL of the floor wire connector on the airbag sensor assembly side OK Resistance Below 1 Ω NG Repair or replace floor wire OK 1191 ...

Page 1193: ... 6 Check floor wire to ground CHECK Measure the resistance between the body ground and each of VUPL SSL and FSL of the floor wire connector on the airbag sensor assembly side OK Resistance 1 MΩ or Higher NG Repair or replace floor wire OK 7 Check floor wire to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and each of VUPL SSL FSL and ESL of the floor wire c...

Page 1194: ...t at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK Neither DTC B1141 33 nor B1140 32 are not output HINT Codes other than code B1141 3...

Page 1195: ...y and the door side airbag sen sor RH For details of the function of each component see OPERATION on page RS 2 DTC B1142 B1143 34 is recorded when a malfunction is detected in the door side airbag sensor RH circuit DTC No DTC Detecting Condition Trouble Area B1142 B1143 34 S Short in door side airbag sensor RH wire harness to B S Short in door side airbag sensor RH wire harness to Ground S Door si...

Page 1196: ... 1025 2 Check wire harness to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and each of DMR and DMR on the airbag sensor assembly side between the door side airbag sensor RH and the airbag sensor assembly OK Voltage Below 1 V NG Go to step 8 OK 3 Check wire harness to ground CHECK Measure the resistance between the body ground and each of DMR and DMR on the...

Page 1197: ... and DMR on the air bag sensor assembly side between the airbag sensor assembly and the door side airbag sensor RH OK Resistance 1 MΩ or Higher NG Go to step 10 OK 5 Check wire harness PREPARATION Using a service wire connect DMR and DMR on the door side airbag sensor RH side between the airbag sensor assem bly and the door side airbag sensor RH CHECK Measure the resistance between DMR and DMR on ...

Page 1198: ... RH DMR DMR DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 997 2005 CELICA RM1131U 6 Check door side airbag sensor RH CHECK Measure the resistance between DMR and DMR of the door side airbag sensor RH OK Resistance 300 1500 Ω NG Replace door side airbag sensor RH OK 1197 ...

Page 1199: ...cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1142 B1143 34 is not output HINT Codes other than ...

Page 1200: ...e ignition switch to ON b Measure the voltage between the body ground and each of DMR and DMR of the front door RH wire connector on the instrument panel wire side OK Voltage Below 1 V NG Repair or replace front door RH wire OK Repair or replace instrument panel wire 9 Check front door RH wire to ground PREPARATION Disconnect the front door RH wire from the instrument panel wire CHECK Measure the ...

Page 1201: ...YSTEM 2005 CELICA RM1131U 10 Check front door RH wire PREPARATION Disconnect the front door RH wire from the instrument panel wire CHECK Measure the resistance between DMR and DMR of the front door RH wire connector on the instrument panel wire side OK Resistance 1 MΩ or Higher NG Repair or replace front door RH wire OK Repair or replace instrument panel wire 1200 ...

Page 1202: ...re PREPARATION a Disconnect the front door RH wire from the instrument panel wire b Using a service wire connect DMR and DMR of the front door RH wire connector on the door side airbag sen sor RH side CHECK Measure the resistance between DMR and DMR of the front door RH wire connector on the instrument panel wire side OK Resistance Below 1 Ω NG Repair or replace front door RH wire OK Repair or rep...

Page 1203: ...bly and the door side airbag sen sor LH For details of the function of each component see OPERATION on page RS 2 DTC B1144 B1145 35 is recorded when malfunction is detected in the door side airbag sensor LH circuit DTC No DTC Detecting Condition Trouble Area B1144 B1145 35 S Short in door side airbag sensor LH wire harness to B S Short in door side airbag sensor LH wire harness to Ground S Door si...

Page 1204: ...I 1025 2 Check wire harness to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and each of DML and DML on the airbag sensor assembly side between the door side airbag sensor LH and the airbag sensor assembly OK Voltage Below 1 V NG Go to step 8 OK 3 Check wire harness to ground CHECK Measure the resistance between the body ground and each of DML and DML on th...

Page 1205: ... DML on the air bag sensor assembly side between the door side airbag sensor LH and the airbag sensor assembly side OK Resistance 1 MΩ or Higher NG Go to step 10 OK 5 Check wire harness PREPARATION Using a service wire connect DML and DML on the door side airbag sensor LH side between the airbag sensor assembly and the door side airbag sensor LH CHECK Measure the resistance between DML and DML on ...

Page 1206: ...LH DML DML DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 1005 2005 CELICA RM1131U 6 Check door side airbag sensor LH CHECK Measure the resistance between DML and DML of the door side airbag sensor LH OK Resistance 300 1500 Ω NG Replace door side airbag sensor LH OK 1205 ...

Page 1207: ... cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1144 B1145 35 is not output HINT Codes other than...

Page 1208: ...e ignition switch to ON b Measure the voltage between the body ground and each of DML and DML of the front door LH wire connector on the instrument panel wire side OK Voltage Below 1 V NG Repair or replace front door LH wire OK Repair or replace instrument panel wire 9 Check front door LH wire to ground PREPARATION Disconnect the front door LH wire from the instrument panel wire CHECK Measure the ...

Page 1209: ...YSTEM 2005 CELICA RM1131U 10 Check front door LH wire PREPARATION Disconnect the front door LH wire from the instrument panel wire CHECK Measure the resistance between DML and DML of the front door LH wire connector on the instrument panel wire side OK Resistance 1 MΩ or Higher NG Repair or replace front door LH wire OK Repair or replace instrument panel wire 1208 ...

Page 1210: ...re PREPARATION a Disconnect the front door LH wire from the instrument panel wire b Using a service wire connect DML and DML of the front door LH wire connector on the door side airbag sen sor LH side CHECK Measure the resistance between DML and DML of the front door LH wire connector on the instrument panel wire side OK Resistance Below 1 Ω NG Repair or replace front door LH wire OK Repair or rep...

Page 1211: ...RH circuit consists of the airbag sensor assembly and the front airbag sensor RH For details of the function of each component see OPERATION on page RS 2 DTC B1156 B1157 15 is recorded when a malfunction is detected in the front airbag sensor RH circuit DTC No DTC Detecting Condition Trouble Area B1156 B1157 15 S Front airbag sensor RH malfunction S Front airbag sensor RH S Airbag sensor assembly ...

Page 1212: ... 1025 2 Check wire harness to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and each of SR and SR on the airbag sensor assembly side be tween the front airbag sensor RH and the airbag sensor assembly OK Voltage Below 1 V NG Go to step 8 OK 3 Check wire harness to ground CHECK Measure the resistance between the body ground and each of SR and SR on the airbag...

Page 1213: ...n SR and SR on the airbag sensor assembly side between the front airbag sensor RH and the airbag sensor assembly OK Resistance 1 MΩ or Higher NG Go to step 10 OK 5 Check wire harness PREPARATION Using a service wire connect SR and SR on the front airbag sensor RH side between the airbag sensor assembly and the front airbag sensor RH CHECK Measure the resistance between SR and SR on the airbag sens...

Page 1214: ...ensor RH SR SR DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 1013 2005 CELICA RM1131U 6 Check front airbag sensor RH CHECK Measure the resistance between SR and SR of the front air bag sensor RH OK Resistance 300 1500 Ω NG Replace front airbag sensor RH OK 1213 ...

Page 1215: ...le to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1156 B1157 15 is not output HINT Codes other than cod...

Page 1216: ...tion switch to ON b Measure the voltage between the body ground and each of SR and SR of the engine room No 2 wire connector on the instrument panel wire side OK Voltage Below 1 V NG Repair or replace engine room No 2 wire OK Repair or replace instrument panel wire 9 Check engine room No 2 wire to ground PREPARATION Disconnect the engine room No 2 wire from the instrument panel wire CHECK Measure ...

Page 1217: ...005 CELICA RM1131U 10 Check engine room No 2 wire PREPARATION Disconnect the engine room No 2 wire from the instrument panel wire CHECK Measure the resistance between SR and SR of the engine room No 2 wire connector on the instrument panel wire side OK Resistance 1 MΩ or Higher NG Repair or replace engine room No 2 wire OK Repair or replace instrument panel wire 1216 ...

Page 1218: ...PREPARATION a Disconnect the engine room No 2 wire from the instru ment panel wire b Using a service wire connect SR and SR of the engine room No 2 wire connector on the front airbag sensor RH side CHECK Measure the resistance between SR and SR of the engine room No 2 wire connector on the instrument panel wire side OK Resistance Below 1 Ω NG Repair or replace engine room No 2 wire OK Repair or re...

Page 1219: ...sor LH circuit consists of the airbag sensor assembly and the front airbag sensor LH For details of the function of each component see OPERATION on page RS 2 DTC B1158 B1159 16 is recorded when malfunction is detected in the front airbag sensor LH circuit DTC No DTC Detecting Condition Trouble Area B1158 B1159 16 S Front airbag sensor LH malfunction S Front airbag sensor LH S Airbag sensor assembl...

Page 1220: ... page DI 1025 2 Check wire harness to B CHECK a Turn the ignition switch to ON b Measure the voltage between the body ground and SL and SL on the airbag sensor assembly side between the front airbag sensor LH and the airbag sensor assembly OK Voltage Below 1 V NG Go to step 8 OK 3 Check wire harness to ground CHECK Measure the resistance between the body ground and SL and SL on the airbag sensor a...

Page 1221: ...n SL and SL on the airbag sensor assembly side between the front airbag sensor LH and the airbag sensor assembly OK Resistance 1 MΩ or Higher NG Go to step 10 OK 5 Check wire harness PREPARATION Using a service wire connect SL and SL on the front airbag sensor LH side between the airbag sensor assembly and the front airbag sensor LH CHECK Measure the resistance between SL and SL on the airbag sens...

Page 1222: ...ensor LH SL SL DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 1021 2005 CELICA RM1131U 6 Check front airbag sensor LH CHECK Measure the resistance between SL and SL of the front air bag sensor LH OK Resistance 300 1500 Ω NG Replace front airbag sensor LH OK 1221 ...

Page 1223: ...le to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ON and wait at least for 10 se conds b Clear the DTC stored in memory See page DI 884 c Turn the ignition switch to LOCK and wait at least for 10 seconds d Turn the ignition switch to ON and wait at least for 10 se conds e Check the DTC See page DI 884 OK DTC B1158 B1159 16 is not output HINT Codes other than cod...

Page 1224: ...he ignition switch to ON b Measure the voltage between the body ground and SL and SL of the engine room main wire connector on the instrument panel wire side OK Voltage Below 1 V NG Repair or replace engine room main wire OK Repair or replace instrument panel wire 9 Check engine room main wire to ground PREPARATION Disconnect the engine room main wire from the instrument pan el wire CHECK Measure ...

Page 1225: ...SL and SL of the engine room main wire connector on the instrument panel wire side OK Resistance 1 MΩ or Higher NG Repair or replace engine room main wire OK Repair or replace instrument panel wire 11 Check engine room main wire PREPARATION a Disconnect the engine room main wire from the instru ment panel wire b Using a service wire connect SL and SL of the engine room main wire connector on the f...

Page 1226: ...e increase circuit DC DC converter in the airbag sensor assembly in case the source voltage drops When the battery voltage drops the voltage increase circuit DC DC converter functions to increase the voltage of the SRS to normal voltage The diagnosis system malfunction display for this circuit is differ from the other circuits in that when the SRS warning light remains on and the DTC shows a norma...

Page 1227: ...ad See page SR 13 c Disconnect the connector of the front passenger airbag assembly See page RS 27 d Disconnect the connector of the side airbag assembly RH and LH See page RS 40 e Disconnect the connector of the seat belt pretensioner RH and LH See page BO 109 f Disconnect the connectors of the airbag sensor assembly See page RS 53 g Disconnect the connector of the front airbag sensor RH and LH S...

Page 1228: ...OCK b Connect the steering wheel pad connector c Connect the front passenger airbag assembly connector d Connect the side airbag assembly connectors e Connect the seat belt pretensioner connectors f Connect the airbag sensor assembly connectors g Connect the front airbag sensor connectors h Connect the side airbag sensor assembly connectors i Connect the door side airbag sensor connectors j Turn t...

Page 1229: ...Warning Light Circuit Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter When the SRS is normal the SRS warning light lights up for approx 6 seconds after the ignition switch is turned from the LOCK position to ON position and then turns off automatically If there is a malfunction in the SRS the SRS warning light lights up to inform the driver of the abnormal...

Page 1230: ... page DI 1025 2 Does SRS warning light turn off PREPARATION a Turn the ignition switch to LOCK b Disconnect the negative terminal cable from the bat tery and wait at least for 90 seconds c Disconnect the airbag sensor assembly connector d Connect the negative terminal cable to the battery CHECK Check operation of SRS warning light NO Check SRS warning light circuit or terminal AB circuit of DLC3 Y...

Page 1231: ...burnt out even if it appears to be OK during visual inspection S If fuse is OK install it NG Go to step 5 OK 2 Prepare for inspection See step 1 on page DI 1025 3 Check SRS warning light circuit PREPARATION a Connect the negative terminal cable to the battery b Turn the ignition switch to ON CHECK Measure the voltage between the body ground and LA terminal of the harness side connector of the airb...

Page 1232: ...oes SRS warning light come on PREPARATION a Disconnect the negative terminal cable from the bat tery b Connect the airbag sensor assembly connectors c Connect the negative terminal cable to the battery and wait at least for 2 seconds d Turn the ignition switch to ON CHECK Check operation of the SRS warning light NO Check terminal LA of airbag sensor assembly If normal replace airbag sensor assembl...

Page 1233: ... SUPPLEMENTAL RESTRAINT SYSTEM 2005 CELICA RM1131U 5 Is new AM2 fuse burnt out again NO Using simulation method reproduce malfunc tion symptoms See page IN 20 YES Check harness between AM2 fuse and SRS warning light 1232 ...

Page 1234: ...C TC 4 A IE DIAGNOSTICS SUPPLEMENTAL RESTRAINT SYSTEM DI 1033 2005 CELICA RM1131U TC Terminal Circuit CIRCUIT DESCRIPTION DTC output mode is set by connecting terminal TC and CG of the DLC3 the airbag sensor assembly The DTCs are displayed by blinking the SRS warning light WIRING DIAGRAM DI6Q0 19 1233 ...

Page 1235: ...1 Does SRS warning light light up for approx 6 seconds CHECK Check operation of the SRS warning light after ignition switch is turned from LOCK position to ON position NO Check SRS warning light system See page DI 1028 YES 2 Check voltage between terminal TC and CG of DLC3 PREPARATION Turn the ignition switch to ON CHECK Measure the voltage between terminal TC and CG of DLC3 OK Voltage 10 14 V OK ...

Page 1236: ...able from the bat tery and wait at least for 90 seconds c Disconnect the airbag sensor assembly connector d Insert service wire into terminal TC from back side as shown in the illustration e Connect the airbag sensor assembly connector with ser vice wire f Connect the negative terminal cable to the battery g Turn the ignition switch to ON and wait at least for 60 se conds h Connect service wire of...

Page 1237: ...l Tc of airbag sensor assembly and body ground PREPARATION a Turn the ignition switch to LOCK b Disconnect the negative terminal cable from the bat tery and wait at least for 90 seconds c Disconnect the airbag sensor assembly connector CHECK Check resistance between terminal TC of the airbag sensor as sembly connector and the body ground OK Resistance 1 MΩ or Higher NG Repair or replace harness or...

Page 1238: ...les in this manual with the page number indicated in the bottom portion See the indicated pages for detailed explanations 1 2 3 4 5 6 7 8 9 10 Step 2 5 8 10 Diagnostic steps permitting the use of the hand held tester P DI 1038 P DI 1039 P DI 1044 P DI 1044 P IN 20 P DI 1048 P DI 1050 DI 1087 OK NG Symptom occurs Malfunction code Inside DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1037 2005 CELICA R...

Page 1239: ...ontrol again j Yes j No j Cancel does not occur j With brake ON j Except D position shift j At 40 km h 25 mph or less j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to deceleration side j Hunting occurs j O D cut off does not occur j O D does not return j Switch malfunction j SET j ACCEL j COAST j RESUME j CANCEL j Cruise MAIN indicator l...

Page 1240: ...FF HINT If the indicator check failed proceed to troubleshooting See page BE 46 for the combination meter section b Check the DTC HINT If a malfunction occurs in the No 1 vehicle speed sensor or ac tuator etc during cruise control driving the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunc tion At the same time t...

Page 1241: ...wn in the illustration 2 USING HAND HELD TESTER a Hook up the hand held tester to the DLC3 b Monitor the ECU data by following the prompts on the tes ter screen HINT Hand held tester has a Snapshot function which records the monitored data Please refer to the hand held tester operator s manual for fur ther details 3 DTC CLEARANCE ERASE MODE HINT When operating the erase mode diagnosis detection do...

Page 1242: ...es while the control switch is pushed up to RES ACC and that the vehicle cruises at the set speed when the switch is released 4 Momentarily push up the control switch to the RES ACC position and then immediately release it Check that the vehicle speed increases by about 1 5 km h Tap up function c Inspect the COAST switch 1 Press the main switch button to ON 2 Drive at a desired speed 40 km h 25 mp...

Page 1243: ... T S Push the main switch button to OFF S Pull the cruise control switch to CANCEL e Inspect the RESUME switch 1 Press the main switch button to ON 2 Drive at a desired speed 40 km h 25 mph or high er 3 When performing one of the followings action check that the cruise control system is cancelled and that the normal driving mode is reset S Depress the brake pedal S Depress the clutch pedal M T S S...

Page 1244: ... sec 0 25 sec Turn clutch switch OFF Depress clutch pedal Clutch switch circuit is normal DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1043 2005 CELICA RM1131U 5 INPUT SIGNAL CHECK HINT 1 For check No 1 to No 3 Turn ignition switch ON 2 For check No 4 S Jack up the vehicle S Start the engine S Shift to D position a Push down the control switch to push up the SET COAST or push up the RES ACC positio...

Page 1245: ...STOP Fuse S Stop light switch S Actuator magnetic clutch S Harness or connector between cruise control ECU and actuator magnetic clutch actuator magnetic clutch and body ground S Cruise control ECU 14 DI 1056 Actuator Mechanical Malfunction S Actuator motor actuator lock motor arm S Cruise control ECU 21 DI 1058 Open in Vehicle Speed Sensor Circuit S Combination meter S Harness or connector betwee...

Page 1246: ...Cruise Control Switch Cruise Control ECU Instrument Panel Junction Block D C C ECU IG Fuse D WARNING Fuse D STOP Fuse Cruise Control Actuator Stop Light Switch DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1045 2005 CELICA RM1131U PARTS LOCATION 1245 ...

Page 1247: ...B Ignition switch ON 10 16 V Ignition switch ON Connect terminals Tc and E1 of diagnostic check connector Below 1 V ECT GND C18 6 C18 16 Y W B During driving Gear position 3rd 10 16 V During driving Gear position O D Below 1 V MC GND C18 7 C18 16 R W W B During cruise control driving COAST switch held ON 9 15 V During cruise control driving ACC switch held ON Below 1 V L GND C18 8 C18 16 G B W B D...

Page 1248: ...lve fully opened 10 16 V Ignition switch ON Throttle valve fully closed Below 1 5 V OD GND C18 14 C18 16 B W B During cruise control driving O D switch ON 10 16 V During cruise control driving O D switch OFF 3rd driving Below 1 V MO GND C18 15 C18 16 P L W B During cruise control driving ACC switch hold ON 9 15 V During cruise control driving COAST switch hold ON Below 1 V GND Body Ground C18 16 B...

Page 1249: ...pedal is depressed 1 Cruise Control Cable 2 Stop Light Switch Circuit 3 Actuator Motor Circuit 4 Cruise Control ECU DI 1050 DI 1068 DI 1078 DI 1078 Cruise control cannot be cancelled even when transmission is shifted to N position 1 Cruise Control Cable 2 Park Neutral Position Switch Circuit A T 3 Actuator Motor Circuit 4 Cruise Control ECU DI 1050 DI 1075 DI 1078 DI 1078 Cruise control cannot be ...

Page 1250: ...049 2005 CELICA RM1131U DTC is not output or is output when should not be 1 Diagnosis Circuit 2 Cruise Control ECU DI 1085 DI 1078 Cruise MAIN indicator light remains ON or fails to come on 1 Cruise MAIN Indicator Light Switch Circuit DI 1083 1249 ...

Page 1251: ... from the ECU Acceleration and deceleration signals are trans mitted according to the changes in the Duty Ratio See below Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle For example if A is the period of continuity in one cycle B is the period of non continuity DTC No Detection Item Trouble Area 11 Short in actuator motor circuit S Actuator motor S Harness or connec...

Page 1252: ...tor CHECK Measure the resistance between terminal 1 and 2 HINT If the control plate is in fully opened or fully closed positions the resistance cannot be measured OK Resistance more than 4 2 Ω NG Replace cruise control actuator OK 2 Check for open and short in harness and connectors between cruise control ECU and actuator motor See page IN 30 NG Repair or replace harness or connector OK Check and ...

Page 1253: ...on and the power supply to the magnetic clutch is mechanically cut and therefore the magnetic clutch is turned OFF When driving downhill if the vehicle speed exceeds the set speed by 15 km h 9 mph the ECU turns the safety magnet clutch OFF If the vehicle speed later drops by 10 km h 6 mph from that speed cruise control at the set speed is resumed DTC No Detection Item Trouble Area 12 43 Short in a...

Page 1254: ...B A A J9 Junction Connector W B IG3 10 W B 3 4 R Y IG3 4 R Y G B 4 3 8 L to Stop Fuse To Stop Lights 2 1 L GND C5 Cruise Control Actuator STP Instrument Panel J B IK IO IF G W 2 9 14 11 G W G W DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1053 2005 CELICA RM1131U WIRING DIAGRAM 1253 ...

Page 1255: ...P fuse from the instrument panel junc tion block CHECK Check fuse continuity OK There is continuity NG Replace STOP fuse OK 2 Check stop light switch PREPARATION Disconnect the stop light switch connector CHECK Check continuity between terminals Switch position Continuity Switch pin free Brake pedal depressed 1 2 Switch pin pushed in Brake pedal released 3 4 NG Replace stop light switch OK 1254 ...

Page 1256: ...the actuator connector CHECK Measure the resistance between terminal 3 and 4 OK Resistance 34 65 42 35 Ω NG Replace cruise control actuator OK 4 Check for open and short in harness and connectors between cruise control ECU and actuator magnetic clutch actuator magnetic clutch and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace cruise control ECU See page I...

Page 1257: ...r motor S Cruise control ECU WIRING DIAGRAM See page DI 1052 INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation PREPARATION a Turn ignition switch OFF b Disconnect the actuator connector CHECK a Connect the battery positive lead to terminal 3 and the battery negative lead to terminal 4 of the actuator NOTICE Do not connect the high tension cables to the wrong bat tery termi...

Page 1258: ...nnect the battery negative lead to terminal 2 and 4 of the actuator OK Control arm moves to fully open side CHECK Connect the battery positive lead to terminal 2 and 3 of the actuator and connect the battery negative lead to terminal 1 and 4 of the actuator OK Control arm moves to fully closed side NG Replace cruise control actuator OK 3 Check harness and connector between cruise control ECU and c...

Page 1259: ...tor shaft is driven by the gear of the transmission For each rotation of the shaft the vehicle speed sensor sends a 4 pulse signal through the combination meter to the cruise control ECU See the following installation ECU calculates the vehicle speed from this pulse frequency DTC No Detection Item Trouble Area 21 Speed signal is not input to the cruise control ECU while cruise control is set S Com...

Page 1260: ...n Meter 9 W R IF IM 5 10 12 C18 Cruise Control ECU 12 IF V1 Speed Sensor SPD 1 10 2 3 1 2 Instrument Panel J B Engine Room J B R L AM1 C 5 IK L R IG1 2 W I10 Ignition Switch 1 1 Engine Room J B B R B R W B Instrument Panel J B 6 W R 8 20 LG B LG B LG W R D D J8 J C DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1059 2005 CELICA RM1131U WIRING DIAGRAM 1259 ...

Page 1261: ...above 40 km h 25 mph and below 40 km h 25 mph OK Vehicle speed below 40 km h 25 mph Indicator light remains on Vehicle speed above 40 km h 25 mph Indicator light blinks OK Check and replace cruise control ECU See page IN 30 NG 2 Check speedometer circuit See Combination meter troubleshooting on page BE 46 NG Repair or replace harness connector or com bination meter assembly OK 3 Check harness and ...

Page 1262: ...IAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1061 2005 CELICA RM1131U 4 Check vehicle speed sensor See page BE 50 NG Replace vehicle speed sensor OK Check and replace cruise control ECU See page IN 30 1261 ...

Page 1263: ...page DI 1058 DTC No Detection Item Trouble Area 23 Vehicle speed sensor pulse is abnormal S Vehicle speed sensor S Cruise control ECU WIRING DIAGRAM See page DI 1058 INSPECTION PROCEDURE 1 Check vehicle speed sensor See page BE 50 NG Replace vehicle speed sensor OK Check and replace cruise control ECU See page IN 30 DI08Q 23 1262 ...

Page 1264: ...ch W B A A A J9 J C J10 J C IH W B SET COAST DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1063 2005 CELICA RM1131U Control Switch Circuit Cruise Control Switch CIRCUIT DESCRIPTION This circuit carries the SET COAST RESUME ACCEL and CANCEL signals each voltage to the ECU WIRING DIAGRAM DI08R 37 1263 ...

Page 1265: ...e on the left should be output when each switch is ON The signal should disappear when the switch is turned OFF CANCEL switch The indicator light should go off when the cancel switch is turned ON OK Wait and see NG 2 Check voltage between terminals CCS of cruise control ECU connector and body ground PREPARATION a Remove ECU with connector being connected b Turn ignition switch ON CHECK Measure the...

Page 1266: ...witch connector when control switch is operated Switch position Resistance Ω Neutral No continuity RES ACC 210 270 SET COAST 570 690 CANCEL 1390 1690 NG Replace control switch OK 4 Check harness and connector between cruise control ECU and cruise control switch cruise control switch and body ground See page IN 30 NG Repair or replace harness or connector OK 5 Input signal check See step 1 OK Wait ...

Page 1267: ...the idle switch is turned ON a signal is sent to the ECU The ECU uses this signal to correct the dis crepancy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed Since there will also be a problem when the idle switch malfunctions inspect both the switch and the engine if the idle switch is faulty WIRING DIAGRAM DI3VK 14 126...

Page 1268: ...switch ON CHECK Measure the voltage between terminal IDL of the ECU connec tor and body ground when the throttle valve is fully opened and fully closed OK Throttle valve position Voltage Fully opened 10 14 V Fully closed Below 2 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 2 Check for open and short in harness and connector between cruise control ECU a...

Page 1269: ...ht signal circuit The cancellation occurs when the battery positive voltage is applied to terminal STP When the brake is ON battery positive voltage is applied to terminal STP of the ECU via the stop fuse and the stop light switch and then the ECU turns the cruise control OFF Even if the harness connected to terminal STP has an open circuit the cruise control will be turned OFF Also when the brake...

Page 1270: ... Y 2 4 1 3 S8 Stop Light Switch G B Cruise Control ECU 2 8 C18 C18 G W IK IF IO 9 11 14 G W STP J C J12 J12 A C A C J13 J13 G W BA1 3 W B 1 2 BA1 2 A J14 J C 2 5 2 5 R7 Stop Light RH BL BJ G B L Instrument Panel J B G W G W W B W B B R B R Engine Room J B Instrument Panel J B 1 2 A A G W W B G W DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1069 2005 CELICA RM1131U WIRING DIAGRAM 1269 ...

Page 1271: ...t stop light comes on when the brake pedal is depressed and turns off when the brake pedal is released NG Check stop light system See page BE 2 OK 2 Input signal check CHECK a See input signal check on DI 1039 b Check the indicator light when the brake pedal is de pressed OK The indicator light goes OFF when the brake pedal is depressed OK Proceed to next circuit inspection shown in problem sympto...

Page 1272: ... voltage between terminal STP of the cruise con trol ECU connector and body ground when the brake pedal is depressed and released OK Depressed 10 14 V Released Below 1 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 4 Check for open in harness and connectors between terminal STP of cruise con trol ECU and stop light switch See page IN 30 NG Repair or repl...

Page 1273: ...ise control ECU sends a signal there to suspend the shift up until the vehicle reaches the top of the hill This will provide smooth driving and there is no need for ON OFF overdrive operation Terminal ECT of the cruise control ECU detects the shift change signal output to electronically controlled transmission No 2 solenoid from ECM If the vehicle speeds down and when terminal ECT receives the shi...

Page 1274: ... switch ON OFF NG Check and repair electronically controlled transmission See page DI 666 or DI 755 OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body ground PREPARATION a Remove ECU with connector being connected b Turn the ignition switch ON c Disconnect the ECU connector CHECK Measure the voltage between terminal OD of the harness side connector of E...

Page 1275: ...itch position Voltage ON 8 14 V OFF Below 0 5 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 4 Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transmission solenoid See page IN 30 NG Repair or replace harness or connector OK Check and replace cruise control ECU 5 Check harness and connector between ter...

Page 1276: ... ALT 1 1 Engine Room J B B R B O M T 19 6 IB 7 2C 2C 2C 2F Engine Room J B L W R L R L B W Engine Room J B 18 17 B Y M T BK UP LP 3 7 L R P1 Park Neutral Position Switch 6 C 12 DL RB DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1075 2005 CELICA RM1131U Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION When the shift position is except D a signal is sent from the park neutral position switch ...

Page 1277: ...tion CHECK Check that the starter operates normally and the engine starts NG Proceed to engine troubleshooting See page DI 1 OK 2 Input signal check PREPARATION See input signal check on page DI 1039 CHECK Check the indicator light when shifting into positions except D OK The indicator light goes off when shifting into posi tions except D OK Proceed to next circuit inspection shown in problem symp...

Page 1278: ...al D of ECU connector and body ground when shifting into D position and the other posi tions OK Shift Position Voltage D position 10 14 V Other positions Below 1 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 4 Check harness and connector between cruise control ECU and park neutral position switch See page IN 30 NG Repair or replace harness or connector ...

Page 1279: ...ol driving the cruise control ECU cancels cruise control WIRING DIAGRAM Refer to PNP switch circuit on page DI 1075 INSPECTION PROCEDURE 1 Check starter operation CHECK Check that the starter operates normally and the engine starts NG Proceed to engine troubleshooting OK 2 Input signal check PREPARATION See input signal check on page DI 1039 CHECK Check the indicator lights when clutch pedal is de...

Page 1280: ...ge between terminal D of the cruise control ECU connector and body ground when clutch pedal is de pressed and pushed in OK Condition Voltage Clutch pedal depressed 10 14 V Clutch pedal pushed in Below 1 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 5 Check for open in harness and connector between ECU and C C ECU IG fuse See page IN 30 NG Repair or repl...

Page 1281: ...J C W B A IH B R W B IF Engine Room J B 1 2E 2A 1 1 2 ALT FL MAIN Battery 1 12 10 5 8 1 2 B R DI 1080 DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE 2005 CELICA RM1131U ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies a power to the actuator and sensors etc when terminal GND and the cruise control ECU case are grounded WIRING DIAGRAM DI08X 37 1280 ...

Page 1282: ...inuity of ECU IG fuse OK Continuity NG Check for short in all the harness and compo nents connected to ECU IG fuse OK 2 Check voltage between terminals B and GND of cruise control ECU connector PREPARATION a Remove ECU with connector being connected b Turn ignition switch ON CHECK Measure the voltage between terminal B and GND of the ECU connector OK Voltage 10 14 V OK Proceed to next circuit insp...

Page 1283: ...inal GND of cruise control ECU connector and body ground CHECK Measure the resistance between terminal GND of the ECU con nector and body ground OK Resistance Below 1 Ω NG Repair or replace harness or connector OK Check and repair harness and connector be tween cruise control ECU and battery See page IN 30 1282 ...

Page 1284: ...lay AM1 L R I10 Ignition Switch 2 1 AM1 IG1 W W B B R B R FL MAIN Battery 2E 2A 1 2 ALT 1 1 Engine Room J B B R IF 12 DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1083 2005 CELICA RM1131U CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned ON CRUISE MAIN indicator light comes on WIRING DIAGRAM DI090 59 1283 ...

Page 1285: ...e ignition switch ON CHECK Measure the voltage between terminal PI and GND of the cruise control ECU connector when main switch is ON and OFF OK Switch position Voltage OFF 10 16 V ON Below 1 2 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 2 Check combination meter See page BE 46 NG Replace combination meter OK Check and replace cruise control ECU See p...

Page 1286: ... P B 4 II 9 P B 13 TC D1 DLC3 Instrument Panel J B DIAGNOSTICS CRUISE CONTROL SYSTEM 1ZZ FE DI 1085 2005 CELICA RM1131U Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to ECU which outputs DTC WIRING DIAGRAM DI091 36 1285 ...

Page 1287: ...N Turn the ignition switch ON CHECK Measure the voltage between terminal Tc and CG of DLC3 OK Voltage 10 14 V OK Proceed to next circuit inspection shown in problem symptom table See page DI 1048 NG 2 Check harness and connector between cruise control ECU and DLC3 DLC3 and body ground See page IN 30 NG Repair or replace harness or connector OK Check and replace cruise control ECU See page IN 30 12...

Page 1288: ...hrottle link are properly installed and that the cable and link are connected correctly b Check that the actuator and the bell crank operate smoothly c Check that the cable is not too loose or too tight OK Freeplay less than 10 mm HINT S If the control cable is too loose the vehicle s loss of speed going uphill will be large S If the control cable is too tight the idle RPM will become high DI092 1...

Page 1289: ...ion titles in this manual with the page number indicated in the bottom portion See the indicated pages for detailed explanations 1 2 3 4 5 6 7 8 9 10 Step 2 5 8 10 Diagnostic steps permitting the use of the hand held tester P DI 1089 P DI 1090 P DI 1096 P DI 1096 P IN 20 P DI 1099 P DI 1100 DI 1115 OK NG Symptom occurs Malfunction code DI 1088 DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE 2005 CELICA R...

Page 1290: ...e control again j Yes j No j Cancel does not occur j With brake ON j With clutch switch ON j Except D position shift j When control SW turns to CANCEL position j Cruise control malfunction j Slip to acceleration side j Slip to deceleration side j Hunting occurs j O D cut off does not occur j O D does not return j Switch malfunction j SET j ACCEL j COAST j RESUME j CANCEL j Remains ON j Does not co...

Page 1291: ...nal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141 2 format Terminal No Connection Specified Condition Condition 4 Chassis Ground Body Ground 1 Ω or less Always 7 Bus Line Pulse Generation During Communication 16 Battery Positive Body Ground 9 14 V Always HINT If the display shows UNABLE TO CONNECT TO VEHICLE as connecting the hand held tester to the DLC3 and turning the igni...

Page 1292: ...for the combination meter section See page BE 50 d Check the DTC HINT If a malfunction occurs on the speed sensor or on the stop light switch etc during cruise control driving ECU actuates AUTO CANCEL of the cruise control and turns ON and OFF the CRUISE MAIN indicator light to inform the driver of a malfunc tion At the same time the malfunction is stored in the memory as a diagnostic trouble code...

Page 1293: ... min 0_ max 125_ Required throttle opening angle 0_ 84_ Cruise control acti vated CCS READY S Cruise control system standby condition Sub CPU ON or OFF ON OFF Change ON OFF each time Main SW is pressed in 1 CCS READY M Cruise control system standby condition Main CPU ON or OFF ON OFF Change ON OFF each time Main SW is pressed in 1 CANCEL SW CANCEL SW signal ON or OFF ON CANCEL SW ON OFF CANCEL SW ...

Page 1294: ... Disconnect the battery terminals or EFI NO 1 fuse b After completing repairs DTC retained in the memory can be cleared by removing the EFI NO 1 fuse more than 1 minutes with the ignition switch OFF c Check that the normal code is displayed after connecting the fuse 5 PROBLEM SYMPTOM CONFIRMATION ROAD TEST a Inspect the SET switch 1 Push the main switch button to ON 2 Drive at a desired speed 40 k...

Page 1295: ...OAST and the vehicle cruises at the set speed when the switch is released 4 Momentarily push the control switch downward to SET COAST and then immediately release it Check that the vehicle speed decreases by about 1 5 km h Tap down function d Inspect the CANCEL switch 1 Push the main switch button to ON 2 Drive at a desired speed 40 km h 25 mph or high er 3 When operating one of the followings che...

Page 1296: ...ed and that the normal driving mode is reset S Depress the brake pedal S Depress the clutch pedal M T S Shift to except D position A T S Pull the cruise control switch to CANCEL 4 After the control switch is pulled up to RES ACC at the driving speed of more than 40 km h 25 mph check that the vehicle restores the speed prior to the cancellation 6 INPUT SIGNAL CHECK Using hand held tester a Connect ...

Page 1297: ...low and proceed to the appropriate page DTC No See Page Circuit Inspection Trouble Area P0500 21 DI 1100 Vehicle Speed Sensor A S Combination meter S Vehicle speed sensor S Wire harness or connector S ECM P0503 23 DI 1100 Vehicle speed sensor A Intermittent Erratic High P0571 52 DI 1101 Brake switch A Circuit S Stop light switch S Wire harness or connector S ECM P0607 54 DI 1105 Control module per...

Page 1298: ...sor Park Neutral Position Switch A T ECM Combination Meter CRUISE Main Indicator Light Cruise Control Switch Instrument Panel Junction Block Stop Light Switch Cruise Control Clutch Switch M T DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE DI 1097 2005 CELICA RM1131U PARTS LOCATION 1297 ...

Page 1299: ...8 24 E12 1 W G BR Ignition switch ON 9 14 V Ignition switch ON CANCEL switch hold ON 6 10 1 V Ignition switch ON SET COAST switch hold ON 4 7 1 V Ignition switch ON RES ACC switch hold ON 2 1 4 V Ignition switch ON MAIN switch hold ON Below 1 V PI E1 E8 13 E12 1 Y G BR Ignition switch ON Cruise control main switch ON 0 3 V Ignition switch ON Cruise control main switch OFF 9 14 V ST1 E1 E8 12 E12 1...

Page 1300: ...sed 1 Stop Light Switch Circuit 2 ECM DI 1101 DI 293 Cruise control cannot be cancelled even when the transmission is shifted to N position 1 Park Neutral Position Switch Circuit A T 2 Clutch Switch Circuit M T 3 ECM DI 738 or DI 825 DI 1106 DI 293 Control switch does not operate SET COAST ACC RES CANCEL not possible 1 Cruise Control Switch Circuit 2 ECM DI 1063 DI 293 SET possible at 40 km h 25 m...

Page 1301: ...e page DI 552 DTC No DTC Detecting Condition Trouble Area P0500 21 P0503 23 No vehicle speed sensor signal to ECM under following condi tions a and b 2 trip detection logic f Park Neutral position switch is OFF g Vehicle is being driven S Combination meter S Harness or connector between ECM and vehicle speed sen sor S Vehicle speed sensor S ECM WIRING DIAGRAM See page DI 552 INSPECTION PROCEDURE S...

Page 1302: ...ise control A fail safe function is provided to maintain normal driving even if there is a malfunction in the stop light signal circuit The cancel condition occurs when the battery positive voltage is supplied to terminal STP When the stop light switch is on battery positive voltage is applied through the STOP fuse and the stop light switch to terminal STP of the ECM and the ECM turns the cruise c...

Page 1303: ...n the ignition switch ON and push the hand held tester main switch ON CHECK Select the item STOP LIGHT SW in the DATA LIST and read the displayed value OK Brake pedal depressed ON Brake pedal released OFF OK Proceed to next circuit inspection shown in problem symptoms table See page DI 1099 NG 2 Check operation of stop light CHECK Check that the stop light comes on when the brake pedal is depresse...

Page 1304: ...and re leased OK Depressed 10 14 V Released Below 1 V OK Proceed to next circuit inspection shown in problem symptoms table See page DI 1099 NG 4 Check voltage between terminal ST1 of ECM connector and body ground PREPARATION a Remove ECM with connectors being connected b Turn the ignition switch ON CHECK Measure the voltage between terminal ST1 of ECM connector and body ground when the brake peda...

Page 1305: ...005 CELICA RM1131U 5 Check wire harness and connector between terminal STP of ECM and stop light switch and terminal ST1 of ECM and stop light switch See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page IN 30 1304 ...

Page 1306: ...ule Performance Abnormal CIRCUIT DESCRIPTION This DTC indicates the internal abnormalities of ECM DTC No DTC Detecting Condition Trouble Area P0607 54 S Cruise control input signal abnormal S Stop light switch input signal abnormal S ECM INSPECTION PROCEDURE Check and replace ECM See page IN 30 DIAJS 02 1305 ...

Page 1307: ... 1 1 2 5 3 AM1 ECU IG 5 A IG1 Relay E8 ECM D AM1 IG1 1 2 I10 Ignition SW 10 M T M T M T M T M T M T M T DI 1106 DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE 2005 CELICA RM1131U Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed the clutch switch sends a signal to the ECM When the signal is input to the ECM during the cruise control driving the cruise control ECU cancels the c...

Page 1308: ... the indicator lights when clutch pedal is depressed OK The indicator light goes off when the clutch pedal is depressed OK Proceed to next circuit inspection shown in problem symptom table See page DI 1099 NG 2 Inspect clutch switch assy a Disconnect the clutch switch connector b Check that the continuity exists when the clutch switch assy is operated OK Switch Position Specified condition Switch ...

Page 1309: ... CRUISE CONTROL SYSTEM 2ZZ GE 2005 CELICA RM1131U 3 Check for open in harness and connector between ECU and GAUGE fuse See page IN 30 NG Repair or replace harness or connector OK Check and replace ECM See page IN 30 1308 ...

Page 1310: ...II IA IM IK 6 A 5 E8 IK 3 1 2 W B IF W Y G Y G WARNING IG1 Relay Engine Room J B ALT 1 2 1 1 2A 2E 13 CRUISE DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE DI 1109 2005 CELICA RM1131U CRUISE MAIN Indicator Light Circuit CIRCUIT DESCRIPTION When the cruise control main switch is turned off the cruise control does not operate WIRING DIAGRAM DIAJU 03 1309 ...

Page 1311: ...ignition switch ON CHECK Measure the voltage between terminal PI and GND of ECM connector when main switch is turned on and off OK Switch position Voltage OFF 9 14 V ON 0 3 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1099 NG 2 Check combination meter See page BE 50 NG Replace combination meter OK Check and replace ECM See page IN 30 1310 ...

Page 1312: ...CS BR W G BR A A W G IE3 10 22 BR BR IE3 6 EA3 DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE DI 1111 2005 CELICA RM1131U Control Switch Circuit Cruise Control Switch CIRCUIT DESCRIPTION This circuit carries the SET COAST RESUME ACCEL and CANCEL signals each voltage to ECM WIRING DIAGRAM DIAJV 03 1311 ...

Page 1313: ...e ECM with connectors being connected b Turn the ignition switch ON CHECK Measure the voltage between terminal CCS of ECM connector and body ground when each of the SET COAST RES ACC and CANCEL is turned ON Switch position Voltage V Neutral 9 14 V RES ACC 2 1 4 V SET COAST 4 7 1 V CANCEL 6 10 1 V NG Proceed to next circuit inspection shown in problem symptoms table See page DI 1099 OK 1312 ...

Page 1314: ...he control switch is operated OK Switch position Resistance Ω Neutral No continuity RES ACC 210 270 SET COAST 560 700 CANCEL 1380 1700 b Check the continuity between terminal 4 and 5 of the con trol switch connector when main switch is held on and off OK Switch position Tester connection Specified condition OFF 4 5 No continuity ON 4 5 Continuity NG Replace control switch OK 3 Check harness and co...

Page 1315: ...I 1114 DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE 2005 CELICA RM1131U 4 Check cruise control indicator light See combination meter NG Replace combination meter OK Check and replace ECM See page IN 30 1314 ...

Page 1316: ...TC ECM J3 Junction Connector Cowl Side Panel LH Instrument Panel J B A DIAGNOSTICS CRUISE CONTROL SYSTEM 2ZZ GE DI 1115 2005 CELICA RM1131U DIAGNOSIS CIRCUIT CIRCUIT DESCRIPTION This circuit operates when conducting the DTC check WIRING DIAGRAM DIAJW 03 1315 ...

Page 1317: ...age 10 16 V OK Proceed to next circuit inspection shown in problem symptoms table See page DI 1099 NG 2 Check harness and connector a Check for open and short circuit in the harness and the connector between ECM and DLC3 See page IN 30 b Check for open and short circuit in the harness and the connector between DLC3 and body ground See page IN 30 NG Repair or replace harness or connector OK Proceed...

Page 1318: ...icated pages for detailed explanations 1 2 3 6 5 P IN 20 P DI 1118 P DI 1126 DI 1184 Symptom occur Step 6 8 Diagnostic steps permitting the use of the hand held tester 7 4 Problem Symptoms Table P DI 1124 DIAGNOSTICS BODY CONTROL SYSTEM DI 1117 2005 CELICA RM1131U BODY CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT This ECU is connected to the multiplex communication system Therefore be s...

Page 1319: ...e only Brought in Key Reminder System Malfunction System Outdoor Temperature Fine Cloudy Rainy Snowy V arious Others Hot Warm Cool Cold Approx F C Constant Sometimes times per day month Illuminated Entry System Light Control System Combination Meter Open door warning light Light Auto Turn Off System Power Window Control System Power Door Lock Control System Wireless Door Lock Control System Others...

Page 1320: ... ECU ACC Fuse D DOOR Fuse D BODY ECU IG Fuse D MPX B Fuse D DEF RLY Fuse D Taillight Relay D Defogger Relay D DEF Fuse D TAIL Fuse D DRL No 2 Relay Parking Brake Switch Buckle Switch Seat Belt Occupant Detection Sensor Power Window Master Switch Clock Engine Room R B No 2 D DRL No 2 Relay D DRL No 3 Relay D DRL No 4 Relay DIAGNOSTICS BODY CONTROL SYSTEM DI 1119 2005 CELICA RM1131U PARTS LOCATION 1...

Page 1321: ...ndow Regulator D Power Window Motor Door Courtesy Switch Luggage Compartment Light Door Lock Assembly D Door Lock Motor D Door Unlock Detection Switch D Door Key Lock and Unlock Switch DI 1120 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U 1320 ...

Page 1322: ...switch OFF Approx 5 V Door key lock and unlock switch ON Below 1 V 7 9 ACT ACT Door lock operating 10 14 V 8 11 B E Always 10 14 V 10 11 HRLY E Light control switch OFF or TAIL 10 14 V Light control switch HEAD Below 1 V 11 Body ground E Body ground Always Below 1 V 12 11 ACC E Ignition switch OFF Below 1 V Ignition switch ACC or ON 10 14 V B6 1 11 PWS E GR Sliding roof ECU communication circuit B...

Page 1323: ... P L Headlight dimmer switch LOW Approx 5 7 V Headlight dimmer switch HIGH or FLASH Below 1 V B6 20 11 LSWP E G Except driver s door is unlocked Below 1 V Except driver s door is locked Approx 5 7 V B6 21 11 LSWD E B Driver door is unlocked Below 1 V Driver door is locked Approx 5 7 V B6 22 11 UL2 E Y B Passenger door key lock and unlock switch OFF Approx 5 0 V Passenger door key lock and unlock s...

Page 1324: ...lt buckle switch OFF belt unfastened Approx 5 0 V B7 15 11 L1 E V W Door lock manual switch OFF or UNLOCK Below 1 V Door lock manual switch LOCK Approx 5 0 V B7 16 11 UL1 E P B Door lock manual switch OFF or LOCK Below 1 V Door lock manual switch UNLOCK Approx 5 0 V B7 17 11 DRL E L W Daytime running light system operates when DRL ON Below 1 V B7 4 11 SG4 E W R Sport mode switch OFF 10 14 V Sport ...

Page 1325: ...ning switch circuit 4 Body ECU BE 76 DI 1168 DI 1147 IN 30 Lock or unlock function does not operate 1 Door key lock and unlock switch circuit 2 Door unlock detection switch circuit 3 Body ECU DI 1162 DI 1160 IN 30 Automatic lock function operates even if any door is opened within 30 seconds after all doors are unlocked by wireless door lock control system 1 Door courtesy switch circuit 2 Body ECU ...

Page 1326: ...senger seat belt warning light does not go off 1 Passenger buckle switch circuit 2 Clock 3 Body ECU DI 1149 IN 30 Rear window defogger does not operate 1 Defogger relay circuit 2 Defogger switch 3 Body ECU DI 1170 BE 58 IN 30 Body ECU does not operate 1 Power source circuit 2 Body ECU DI 1126 IN 30 Fuel sender gauge does not operate 1 Fuel sender gauge circuit 2 Combination meter system 3 Body ECU...

Page 1327: ...12 IK 12 II IC 2 AM1 ECU ACC MPX B D 2 B 6 5 3 2 1 IG1 Relay Door Body ECU IG 5 3 C 12 11 8 Body ECU B IG ACC E B 1 Instrument Panel J B Engine Room J B 2 DI 1126 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U CIRCUIT INSPECTION Power Source Circuit CIRCUIT DESCRIPTION This circuit provides power to operate the Body ECU WIRING DIAGRAM 1326 ...

Page 1328: ...Body ECU connector PREPARATION a Turn ignition switch OFF b Disconnect the Body ECU connector CHECK Measure the voltage between terminal B B and E OK Voltage 10 14V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 NG 3 Check wireharness and connector between Body ECU and body ground See page IN 30 NG Repair or replace wire harness or connector OK Check and rep...

Page 1329: ...1 8 Body ECU B IG ACC E B 1 Instrument Panel J B Engine Room J B 2 DI 1128 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Ignition Switch Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned to the ACC position battery voltage is applied to terminal ACC of ECU and when the ignition switch is turned to the ON position battery voltage is applied to terminal IG of ECU WIRI...

Page 1330: ...als ACC IG and E of Body ECU connector PREPARATION Turn ignition switch ON CHECK Measure the voltage between terminal ACC IG and E OK Voltage 10 14V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 NG 3 Check wire harness and connector between Body ECU and body ground See page IN 30 NG Repair or replace wire harness or connector OK Check and repair wire harnes...

Page 1331: ...nt Panel J B Engine Room J B ALT G DI 1130 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Taillight Relay Circuit CIRCUIT DESCRIPTION Taillight relay will be ON by operating the taillight switch The transistor which activates the taillight relay has two sorts one is activated by the taillight switch for fail safe and the other is activated by CPU WIRING DIAGRAM DI6QY 10 1330 ...

Page 1332: ...ay See page BE 18 NG Replace the taillight relay OK 2 Check wire harness and connector between taillight relay and Body ECU battery and taillight relay See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1331 ...

Page 1333: ...eadlight switch The transistor which activates the headlight relay has two sorts one is activated directly by the headlight switch for fail safe and the other is activated by CPU The one activated by CPU has two systems and prevents the headlight to be turned off at the time of trouble with one system in the automatic operation circuit DIAJH 03 1332 ...

Page 1334: ...J4 R W R W H2 Headlight LH LOW Engine Room R B No 2 R L B R FL MAIN Battery 9 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 3 5 3 5 4 DRL NO 4 Relay 2 2 2 2 2 5 3 1 W B II2 IE4 10 R Y J C J C J5 J4 J4 J5 J5 R B 1 2 D B B B H3 Headlight RH HI EB W R W B R Y R Y R B 2 W L R B R Y IE4 8 2 3 W R L L L L 2 1 2 1 L W 2 1 EM 2 1 2 1 E R B R Y W B W B R W 9 IE4 IE5 2 1 2 Instrument Panel J B 2 1 H1 Headlight LH HI W R LG...

Page 1335: ...ytime Running Light Resistor H13 Headlight Control ECU LH 2 IE5 R Y R Y R Y E J5 B J5 B J5 D J4 B J4 R W R L R W II2 9 W L L W 1 3 2 4 W G R W Engine Room R B No 2 A J5 C J4 J C H14 Headlight Control ECU RH 2 1 1 2 5 3 B R L L LG R Engine Room J B 1 5 1 5 4 10 3 R L MAIN HEAD Relay HEAD LVL DRL No 1 HEAD LH LWR HEAD RH LWR 2A 2H 2H 2D 2D 2D 2D 17 2F Instrument Panel J B Body ECU 10 L W 1 IB 17 B7 ...

Page 1336: ...y See page BE 18 NG Replace the headlight relay OK 2 Check wire harness and connector between headlight relay and Body ECU bat tery and headlight relay See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1335 ...

Page 1337: ... Circuit CIRCUIT DESCRIPTION When the light control switch is set to OFF or TAIL after the following conditions are satisfied simultaneously with the ignition switch ON the headlight comes on by control of the body ECU S The parking brake switch is OFF S The generator is ON Engine running DIAJI 03 1336 ...

Page 1338: ...J4 R W R W H2 Headlight LH LOW Engine Room R B No 2 R L B R FL MAIN Battery 9 2 2 2 2 2 2 2 2 2 2 2 2 2 1 1 3 5 3 5 4 DRL NO 4 Relay 2 2 2 2 2 5 3 1 W B II2 IE4 10 R Y J C J C J5 J4 J4 J5 J5 R B 1 2 D B B B H3 Headlight RH HI EB W R W B R Y R Y R B 2 W L R B R Y IE4 8 2 3 W R L L L L 2 1 2 1 L W 2 1 EM 2 1 2 1 E R B R Y W B W B R W 9 IE4 IE5 2 1 2 Instrument Panel J B 2 1 H1 Headlight LH HI W R LG...

Page 1339: ...ytime Running Light Resistor H13 Headlight Control ECU LH 2 IE5 R Y R Y R Y E J5 B J5 B J5 D J4 B J4 R W R L R W II2 9 W L L W 1 3 2 4 W G R W Engine Room R B No 2 A J5 C J4 J C H14 Headlight Control ECU RH 2 1 1 2 5 3 B R L L LG R Engine Room J B 1 5 1 5 4 10 3 R L MAIN HEAD Relay HEAD LVL DRL No 1 HEAD LH LWR HEAD RH LWR 2A 2H 2H 2D 2D 2D 2D 17 2F Instrument Panel J B Body ECU 10 L W 1 IB 17 B7 ...

Page 1340: ... relay See page BE 18 NG Replace the D R L No 2 relay OK 2 Check wire harness and connector between D R L No 2 relay and Body ECU battery and D R L No 2 relay See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1339 ...

Page 1341: ...H HU HL W B J3 Junction Connector 16 IE B6 18 H B6 5 T B6 19 HU R L LG P L 13 14 8 7 A C15 Combination SW DI 1140 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Light Control Switch Circuit CIRCUIT DESCRIPTION This circuit detects the state of the light control switch WIRING DIAGRAM DI5VO 14 1340 ...

Page 1342: ...ol switch See page BE 18 NG Replace the headlight control switch OK 2 Check wire harness and connector between headlight control switch and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1341 ...

Page 1343: ...U HL W B J3 Junction Connector 16 IE B6 18 H B6 5 T B6 19 HU R L LG P L 13 14 8 7 A C15 Combination SW DI 1142 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Headlight Dimmer Switch Circuit CIRCUIT DESCRIPTION This circuit detects the state of the headlight dimmer switch WIRING DIAGRAM DI5VO 15 1342 ...

Page 1344: ...immer switch See page BE 18 NG Replace the headlight dimmer switch OK 2 Check wire harness and connector between headlight dimmer switch and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1343 ...

Page 1345: ...DY CONTROL SYSTEM 2005 CELICA RM1131U Illumination Circuit CIRCUIT DESCRIPTION Receiving the courtesy signal from the Body ECU will make the interior light the ignition light and the courte sy light to come on DI6R0 04 1344 ...

Page 1346: ...2 R W M3 2 P6 2 1 2 6 DOME IK 6 2 B IC 2 L R DCC FL MAIN 2F 7 2A 1 B R Battery 1 w Moon Roof 2 w o Moon Roof Personal Light Instrument Panel J B Engine Room J B L W DOOR ON OFF DIAGNOSTICS BODY CONTROL SYSTEM DI 1145 2005 CELICA RM1131U WIRING DIAGRAM 1345 ...

Page 1347: ...lumination light See page BE 32 NG Replace the failure light OK 3 Check wire harness and connector between each illumination light and Body ECU battery and each illumination light See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1346 ...

Page 1348: ...ICA RM1131U Key Unlock Warning Switch Circuit CIRCUIT DESCRIPTION The key unlock warning switch comes on when the ignition key is inserted in the key cylinder and goes off when the ignition key is removed ECU operates the key confinement prevention function while the key unlock warning switch is on WIRING DIAGRAM DI6R1 06 1347 ...

Page 1349: ...ing switch See page BE 15 NG Replace the key unlock warning switch OK 2 Check wire harness and connector between key unlock warning switch and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1348 ...

Page 1350: ... AM1 Engine Room J B B R DIAGNOSTICS BODY CONTROL SYSTEM DI 1149 2005 CELICA RM1131U Driver Buckle Switch Circuit CIRCUIT DESCRIPTION When the buckle switch of the driver s seat is ON with the ignition switch ON the body ECU sends a signal to turn on the seat belt warning light for the driver s seat and to sound a buzzer When the buckle switch of the passenger seat is ON and the passenger seat bel...

Page 1351: ...k buckle switch See page BE 50 NG Replace the buckle switch OK 2 Check wire harness and connector between buckle switch and body ground See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1350 ...

Page 1352: ... 2F 2 1 3 5 1 2A G Y H6 Horn Low G Y 1 1 H5 Horn High B R L B Engine Room J B 1 w Door Lock Control 2 w o Door Lock Control 1 2 L B 1 1 DIAGNOSTICS BODY CONTROL SYSTEM DI 1151 2005 CELICA RM1131U Horn Circuit CIRCUIT DESCRIPTION The horn is connected to and activated by the body ECU WIRING DIAGRAM DI2A3 11 1351 ...

Page 1353: ...k horn See page BE 131 NG Replace the horn OK 2 Check wire harness and connector between horn relay and body ECU battery and horn relay See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1352 ...

Page 1354: ...Y CONTROL SYSTEM DI 1153 2005 CELICA RM1131U PWS Circuit CIRCUIT DESCRIPTION The body ECU operates the power window and the sliding roof when the ignition switch is ON or within 43 sec after the ignition switch is turned OFF or until the driver s side door is opened in that period WIRING DIAGRAM DI5W4 06 1353 ...

Page 1355: ... INSPECTION PROCEDURE 1 Check wire harness and connector between sliding roof control assembly and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1354 ...

Page 1356: ... DIAGNOSTICS BODY CONTROL SYSTEM DI 1155 2005 CELICA RM1131U Power Window Master Switch Circuit CIRCUIT DESCRIPTION This circuit detects the state of the power window master switch DI6R3 04 1355 ...

Page 1357: ... 2 1 1 5 IA 5 IK II 12 ALT B R B R FL MAIN Battery IE W B FR P W FL P W AM1 5 2 IG1 Relay DEF Relay 3 1 IO IO IN IK 8 11 8 L Y L B B BDR 2 11 12 IG R L R I10 Ignition Switch 2 1 AM1 IG1 J3 J C A W B W B P4 Power Window Lock Switch 10 7 W R W R IF1 3 16 W L 12 1 II IO W B 17 E P7 Power Window Motor LH 5 W Instrument Panel J B Instrument Panel J B IF Engine Room J B C DI 1156 DIAGNOSTICS BODY CONTRO...

Page 1358: ...aster switch See page BE 62 NG Replace the power window master switch OK 2 Check wire harness and connector between power window master switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1357 ...

Page 1359: ...1 10 L R BB1 6 IL 5 L W IH2 1 L W D6 Door Lock Motor RH IL 2 L R IH2 5 L R 6 5 B10 Back Door Lock Motor Instrument Panel J B DI 1158 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Door Lock Motor Circuit CIRCUIT DESCRIPTION When the door switch is set to LOCK the body ECU outputs a signal to lock all of the doors WIRING DIAGRAM DI6R4 07 1358 ...

Page 1360: ... door lock motor See page BE 66 NG Replace the door lock motor OK 2 Check wire harness and connector between door lock motor and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1359 ...

Page 1361: ...NTROL SYSTEM 2005 CELICA RM1131U Door Unlock Detection Switch Circuit CIRCUIT DESCRIPTION The door unlock detection switch is built in the door lock motor assembly This switch is ON when the door lock knob is in the unlock position and OFF when the lock knob is in the lock position The ECU detects the door lock knob conditions in this circuit This system is used as one of the operating conditions ...

Page 1362: ...on switch See page BE 66 NG Replace the door unlock detection switch OK 2 Check wire harness and connector between door unlock detection switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1361 ...

Page 1363: ... and Unlock Switch LH IH IE Instrument Panel J B A A DI 1162 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Door Key Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The door key lock and unlock switch are built in the door key cylinder When the key is turned to the lock side terminal 3 of the switch is grounded and when the key is turned to the unlock side terminal 2 of the switch is groun...

Page 1364: ...ock switch See page BE 66 NG Replace the door key lock and unlock switch NG 2 Check wire harness and connector between door key lock and unlock switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1363 ...

Page 1365: ...B7 20 B7 D4 Door Courtesy Switch RH 1 DI 1164 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Door Courtesy Switch Circuit CIRCUIT DESCRIPTION The door courtesy switch comes on when the door is opened and goes off when door is closed WIRING DIAGRAM DI6R7 07 1364 ...

Page 1366: ...Check that there is a grounding malfunction caused by looseness of the tighten screw NG Install screw OK 3 Check wire harness and connector between courtesy light and body ECU cour tesy switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1365 ...

Page 1367: ... B R B7 2 1 L3 Luggage Compartment Light Instrument Panel J B Engine Room J B LG 2 B LG DI 1166 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Luggage Courtesy Switch Circuit CIRCUIT DESCRIPTION The luggage courtesy switch comes on when luggage compartment door is opened and goes off when lug gage compartment door is closed WIRING DIAGRAM DI6R8 05 1366 ...

Page 1368: ...rtesy switch See page BE 32 NG Replace the luggage courtesy switch OK 2 Check wire harness and connector between luggage courtesy switch and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1367 ...

Page 1369: ...B7 B7 Instrument Panel J B Engine Room J B B 6 DI 1168 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Wireless Door Lock Tuner Circuit CIRCUIT DESCRIPTION The signal from the transmitter will be input to the body ECU through RDA line RDA line is diagnosed by the Body ECU so check DTC also in case of the failure of the wireless function WIRING DIAGRAM DI6R9 06 1368 ...

Page 1370: ...etween terminal PRG of the wireless door lock tuner and PRG of Body ECU OK Continuity NG Repair or replace wire harness OK 2 Check the wireless door lock tuner CHECK Replace the wireless door lock tuner and check if it recovers normally OK Must be recovered normally NG Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 OK Failure of the original wireless door lock ...

Page 1371: ...GND IG RDEF IP W B 12 DEF Relay 1 1 1 IK II AM1 IG1 L R W B R11 R10 BA1 BJ 8 W B W B 7 Rear Window Defogger 2 BB1 B 7 18 IP A9 A9 5 W B A9 3 R R W 11 E I10 Ignition Switch Instrument Panel J B ALT C 5 Instrument Panel J B Engine Room J B A C Switch 1 1 DI 1170 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Rear Defogger Relay Circuit WIRING DIAGRAM DI6RA 05 1370 ...

Page 1372: ...e page BE 58 NG Replace the rear defogger relay OK 2 Check wire harness and connector between rear defogger relay and body ECU front defogger relay and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1371 ...

Page 1373: ...FUA FU FU B7 B7 B7 3 12 13 BR W Y R Y G 1 2 3 DI 1172 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Fuel Sender Gauge Circuit CIRCUIT DESCRIPTION This circuit detects sensor signals from the fuel sender gauge WIRING DIAGRAM DI6RB 04 1372 ...

Page 1374: ...el sender gauge See page BE 50 NG Replace the fuel sender gauge OK 2 Check wire harness and connector between fuel sender gauge and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1373 ...

Page 1375: ...6 EB W B 2 1 R R 6 IE4 2 BLVL Body ECU DI 1174 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Brake Fluid Level Warning Switch Circuit CIRCUIT DESCRIPTION This circuit detects abnormality of the brake fluid level WIRING DIAGRAM DI2AJ 11 1374 ...

Page 1376: ... switch See page BE 50 NG Replace the brake fluid level warning switch OK 2 Check wire harness and connector between brake fluid level warning switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1375 ...

Page 1377: ... Parking Brake Switch 19 R B 1 DI 1176 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Parking Brake Switch Circuit CIRCUIT DESCRIPTION This circuit detects the state of the parking brake switch WIRING DIAGRAM DI5W2 06 1376 ...

Page 1378: ... brake switch See page BE 50 NG Replace the parking brake switch OK 2 Check wire harness and connector between parking brake switch and Body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1377 ...

Page 1379: ...R R 1 E2 E3 BR Y IM IB 12 12 Engine Control Module W B IF 19 5 ODLP ODMS Instrument Panel J B 1 2ZZ GE 2 1ZZ FE E9 16 2 1 2 1 E8 7 E Shift Main SW O D Main SW BR Y 2 DI 1178 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U O D Main Switch Circuit CIRCUIT DESCRIPTION The body ECU detects the state of O D main switch WIRING DIAGRAM DI29Z 11 1378 ...

Page 1380: ... main switch See page DI 746 DI 829 NG Replace the O D main switch OK 2 Check wire harness and connector between O D main switch and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Proceed to next circuit inspection shown on problem symptoms table See page DI 1124 1379 ...

Page 1381: ...GNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Airbag Sensor Assembly Communication Circuit CIRCUIT DESCRIPTION Signals received at the body ECU such as the passenger seat occupant detection sensor signal are trans mitted to the airbag sensor assembly WIRING DIAGRAM DI1T3 07 1380 ...

Page 1382: ...1 Check for open and short in wire harness and connector between body ECU and airbag sensor assembly See page IN 30 NG Repair or replace wire harness and connector OK 2 Check the airbag sensor assembly See page DI 882 NG Replace the airbag sensor assembly OK Replace the body ECU 1381 ...

Page 1383: ...CU A14 Automatic Light Control Sensor CLTB CLTS CLTE B6 B6 B6 DI 1182 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Light Sensor Circuit CIRCUIT DESCRIPTION This circuit detects signals output from the light control sensor WIRING DIAGRAM DI1SU 06 1382 ...

Page 1384: ...RM1131U INSPECTION PROCEDURE 1 Check light sensor See page BE 18 NG Replace the light sensor OK 2 Check wire harness and connector between light sensor and body ECU See page IN 30 NG Repair or replace wire harness or connector OK Replace the body ECU 1383 ...

Page 1385: ...X Body ECU Combination Meter Engine Control Module E8 E8 18 29 1 2 1 2 1 1ZZ FE 2 2ZZ GE DI 1184 DIAGNOSTICS BODY CONTROL SYSTEM 2005 CELICA RM1131U Multiplex Communication Circuit CIRCUIT DESCRIPTION Signals are transmitted between ECM and the combination meter through the communication circuit WIRING DIAGRAM DI6RC 04 1384 ...

Page 1386: ...page DI 1 NG Replace the ECM OK 2 Check combination meter See page BE 50 NG Replace the combination meter OK 3 Check wire harness and connector between combination meter and body ECU ECM and combination meter See page IN 30 NG Repair or replace wire harness or connector OK Replace the body ECU 1385 ...

Page 1387: ...acuum lines properly connected f SFI system wiring connectors fully plugged g Ignition timing check correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 180 SE CONDS 4 INSERT CO HC METER TESTING PROBE AT LEAST 40 cm 1 3 ft INTO TAILPIPE DURING IDLING 5 IMMEDIATELY CHECK CO HC CONCENTRATION AT IDLE AND OR 2...

Page 1388: ...ct timing S Fouled shorted or improperly gapped plugs S Open or crossed high tension cords 5 Incorrect valve clearance 6 Leaky intake and exhaust valves 7 Leaky cylinders Low High Rough idle Fluctuating HC reading 1 Vacuum leaks S PCV hoses S Intake manifold S Throttle body S IAC valve S Brake booster line 2 Lean mixture causing misfire High High Rough idle Black smoke from exhaust 1 Restricted ai...

Page 1389: ...OTICE This measurement must be done in as short a time as pos sible Compression pressure 1ZZ FE 1 500 kPa 15 3 kgf cm2 218 psi 2ZZ GE 1 400 kPa 14 3 kgf cm2 203 psi or more Minimum pressure 1ZZ FE 1 000 kPa 10 2 kgf cm2 145 psi 2ZZ GE 1 000 kPa 10 2 kgf cm2 145 psi Difference between each cylinder 1ZZ FE 100 kPa 1 0 kgf cm2 15 psi or less 2ZZ GE 110 kPa 1 1 kgf cm2 16 psi or less e If the cylinder...

Page 1390: ...ft timing sprock ets are in straight line on the timing chain cover surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the marks as above 3 INSPECT VALVE CLEARANCE a Check only the valves indicated S Using a feeler gauge measure the clearance be tween the valve lifter and camshaft S Record the out of specification valve clearance measurements They will be us...

Page 1391: ...ming chain and camshaft tim ing sprockets c Remove the 2 bolts and chain tensioner d Remove the camshaft and timing sprocket assemblies See page EM 44 1 19 camshaft bearing cap bolts 2 9 camshaft bearing caps No 1 No 3 3 Exhaust camshaft and timing sprocket assembly 4 Intake camshaft and timing sprocket assembly HINT When holding the timing chain disconnect the timing chain from the camshaft timin...

Page 1392: ... mm 0 0008 in from 5 060 mm 0 1992 in to 5 740 mm 0 2260 in 5 2ZZ GE ADJUST VALVE CLEARANCE a Set the SST 1 Turn the crankshaft so that the related rocker arm where the valve clearance is adjusted is fully pushed down NOTICE Remove the spark plug and take off the compression 2 Insert SST into the plug tube SST 09248 77010 09248 07010 NOTICE S SST cannot be inserted unless the set screw is loos ene...

Page 1393: ...t the adjusting shim is removed HINT S Setting SST from the right above makes the removal easy S If there is not enough room reset SST 2 Determine the size of the replaced shim according to these Formula or Charts S Using dial indicator measure the thickness of the removed shim S Calculate the thickness of a new shim so the valve clearance comes within the specified value T Thickness of used shim ...

Page 1394: ... 2110 5 380 0 2118 5 400 0 2126 5 420 0 2134 5 440 0 2142 5 460 0 2150 5 480 0 2157 5 500 0 2165 5 520 0 2173 5 060 0 1992 5 080 0 2000 5 100 0 2008 5 120 0 2016 5 140 0 2024 5 160 0 2031 5 180 0 2039 5 200 0 2047 5 220 0 2055 5 240 0 2063 5 260 0 2071 5 280 0 2079 1ZZ FE Valve Lifter Selection Chart Intake Intake valve clearance Cold 0 15 0 25 mm 0 006 0 010 in EXAMPLE The 5 250 mm 0 2067 in lift...

Page 1395: ...2110 5 380 0 2118 5 400 0 2126 5 420 0 2134 5 440 0 2142 5 460 0 2150 5 480 0 2157 5 500 0 2165 5 520 0 2173 5 060 0 1992 5 080 0 2000 5 100 0 2008 5 120 0 2016 5 140 0 2024 5 160 0 2031 5 180 0 2039 5 200 0 2047 5 220 0 2055 5 240 0 2063 5 260 0 2071 5 280 0 2079 1ZZ FE Valve Lifter Selection Chart Exhaust Exhaust valve clearance Cold 0 25 0 35 mm 0 010 0 014 in EXAMPLE The 5 340 mm 0 2102 in lif...

Page 1396: ... 180 0 0858 2 200 0 0866 2 220 0 0874 2 240 0 0882 2 260 0 0890 Thickness 34 36 28 30 32 38 40 42 48 54 50 44 46 2 280 0 0898 2 300 0 0906 2 340 0 0921 Thickness Shim No 2 320 0 0913 2 360 0 0929 2 380 0 0937 2 400 0 0945 2 420 0 0953 2 440 0 0961 2 460 0 0969 2 480 0 0976 2 500 0 0984 2 520 0 0992 2 540 0 1000 52 Shim No 56 58 60 62 64 66 68 70 72 74 76 78 80 Thickness 2 560 0 1008 2 580 0 1016 2...

Page 1397: ...2 180 0 0858 2 200 0 0866 2 220 0 0874 2 240 0 0882 2 260 0 0890 Thickness 34 36 28 30 32 38 40 42 48 54 50 44 46 2 280 0 0898 2 300 0 0906 2 340 0 0921 Thickness Shim No 2 320 0 0913 2 360 0 0929 2 380 0 0937 2 400 0 0945 2 420 0 0953 2 440 0 0961 2 460 0 0969 2 480 0 0976 2 500 0 0984 2 520 0 0992 2 540 0 1000 52 Shim No 56 58 60 62 64 66 68 70 72 74 76 78 80 Thickness 2 560 0 1008 2 580 0 1016 ...

Page 1398: ...eck that the matchmarks are on the timing chain and camshaft timing sprockets h Install the chain tensioner See page EM 26 i Recheck the valve clearance See procedure in step 3 j Check the valve timing See page EM 26 7 2ZZ GE REINSTALL ADJUSTING SHIM a Lift the rocker arm to make a room and use SST install the adjusting shim HINT S Setting SST from the right above makes the removal easy S To remov...

Page 1399: ...andard shim of 2 400 mm 0 0945 in thickness at low temperature and install the rocker arm b While pressing the rocker arm measure the clearance A of valve b in the condition that a clearance of the other value is 0mm 0 in c To adjust the valve hight replace a shim of valve b with a shim that has thickness of t1 t1 A 2 400 d After adjusting the valve hight adjust the clearance as de scribed from st...

Page 1400: ... scan tool to the DLC3 b Please refer to the TOYOTA hand held tester or OBDII scan tool operator s for further details 3 CONNECT TIMING LIGHT TO ENGINE 4 INSPECT IGNITION TIMING Using a timing light check the ignition timing Ignition timing 1ZZ FE 10 18 BTDC idle 2ZZ GE 8 12 BTDC idle Transmission in neutral position HINT After engine rpm is kept at 1 000 1 300 rpm for 5 seconds check that it retu...

Page 1401: ...ansmission in neutral position i Air conditioning switched OFF 2 CONNECT TOYOTA HAND HELD TESTER OR OBDII SCAN TOOL a Connect the TOYOTA hand held tester or OBDII scan tool to the DLC3 b Please refer to the TOYOTA hand held tester or OBDII scan tool operator s manual for further details 3 INSPECT IDLE SPEED a Race the engine at 2 500 rpm for approx 90 seconds b Check the idle speed Idle speed w Co...

Page 1402: ...RH Engine Mounting Insulator 52 530 38 52 530 38 2ZZ GE RH Engine Mounting Insulator 52 530 38 RH Engine Under Cover N m kgf cm ft lbf Specified torque 52 530 38 52 530 38 52 530 38 52 530 38 2ZZ GE Air Switching Valve 2ZZ GE Front Exhaust Pipe z Gasket 43 440 32 O Ring O Ring Non reusable part z 43 440 32 43 440 32 zGasket EM 16 ENGINE MECHANICAL TIMING CHAIN 2005 CELICA RM1131U TIMING CHAIN COMP...

Page 1403: ... 9 0 90 80 in lbf Chain Tensioner Slipper Timing Chain 54 551 40 Valve Timing Controller Assembly Camshaft Timing Sprocket No 2 Cylinder Head Cover Ignition Coil w Igniter x5 Cylinder Head Cover PCV Hose Gasket Crankshaft Timing Sprocket Chain Vibration Dumper Crank Angle Sensor Plate N m kgf cm ft lbf Specified torque zNon reusable part Wire Harness Protector 13 133 10 18 5 189 14 9 0 90 80 in lb...

Page 1404: ...shaft Pulley x6 x4 Water Pump Pulley Water Pump O Ring z Camshaft Timing Sprocket Crankshaft Position Sensor 9 0 90 80 in lbf Chain Tensioner Slipper Timing Chain 54 551 40 Valve Timing Controller Assembly Crank Angle Sensor Plate Chain Vibration Dumper Crankshaft Timing Sprocket Oil Dipstick z O Ring Oil Guide N m kgf cm ft lbf Specified torque zNon reusable part O Ring z Exhaust Manifold Upper H...

Page 1405: ...rough bolts and disconnect the PS pump from the engine See page SR 26 HINT Put aside the pump and suspend it to the cowl with a string 8 REMOVE RH ENGINE MOUNTING INSULATOR a Set the jack to the engine HINT Place a wooden block between the jack and engine b 1ZZ FE Remove the 4 bolts 2 nuts and RH engine mounting insu lator c 2ZZ GE Remove the 5 bolts 2 nuts and RH engine mounting insu lator 9 1ZZ ...

Page 1406: ...om the No 1 ventilation pipe e Remove the No 1 ventilation pipe and gasket f Remove the 9 bolts wire harness protector cylinder head cover and gasket g Remove the O ring from the cylinder head cover 11 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover b Check that the point marks of the camshaft timing sprock ets are...

Page 1407: ...e the 3 bolts and mounting bracket b 2ZZ GE Remove the 4 bolts and mounting bracket 16 2ZZ GE REMOVE FRONT EXHAUST PIPE See page EM 44 17 2ZZ GE REMOVE EXHAUST MANIFOLD STAY See page EM 44 18 2ZZ FE REMOVE EXHAUST MANIFOLD See page EM 44 19 REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner 20 REMOVE WATER PUMP See page CO 5 21 1ZZ FE REMOVE TIMING CHAIN COVER a Remove the 11 bolts and n...

Page 1408: ... TIMING SPROCKET If the crankshaft timing sprocket cannot be removed by hand use 2 screwdrivers NOTICE Position shop rags as shown to prevent damage 26 REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper 27 REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt valve timing controller assemb...

Page 1409: ...3 or more places se lected at random b Wrap the chain around the timing sprocket c Using a vernier calipers measure the timing sprocket di ameter with the chain NOTICE Vernier calipers must contact the chain rollers for measur ing Minimum sprocket diameter w Chain Camshaft 97 3 mm 3 831 in Crankshaft 51 6 mm 2 031 in If the diameter is less than minimum replace the chain and sprockets 2 INSPECT CH...

Page 1410: ...PECT CHAIN TENSIONER a Check that the plunger moves smoothly when the ratchet pawl is raised with your finger b Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger 4 INSPECT OIL JET See page LU 11 1409 ...

Page 1411: ... tap out the oil seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the timing chain cover edge SST 09309 37010 3 Apply MP grease to the oil seal lip b If timing chain cover is installed to the cylinder block 1 Using a knife cut off the oil seal lip 2 Using a screwdriver pry out the oil seal NOTICE Be careful not to damage the crankshaft Tape the screw driver tip 3...

Page 1412: ...ush valve timing controller assembly to the cam shaft forcibly when installing it c Align the knock pin hole in the camshaft timing sprocket with the knock pin of the camshaft and exhaust the sprocket to the camshaft d Temporarily install the timing sprocket bolt e Hold the hexagon wrench head portion of the camshaft with a wrench and tighten the timing sprocket bolt Torque 54 N m 551 kgf cm 40 ft...

Page 1413: ...SPROCKET a Install the timing chain on the crankshaft timing sprocket with the yellow color link aligned with the timing mark on the crankshaft timing sprocket HINT If necessary install the sprocket with SST SST 09223 22010 b 1ZZ FE Install the timing chain on the camshaft timing sprockets with the yellow color links aligned with the timing marks on the camshaft timing sprockets c 2ZZ GE Install t...

Page 1414: ...d crankshaft timing sprocket 5 INSTALL CHAIN TENSIONER SLIPPER a Install the slipper with the bolt Torque 1ZZ FE 18 5 N m 189 kgf cm 14 ft lbf 2ZZ GE 20 5 N m 209 kgf cm 15 ft lbf b Check that the slipper moves is caught on the cylinder head stopper NOTICE DO not turn the crankshaft 6 INSTALL CRANK ANGLE SENSOR PLATE Install the plate with the F mark facing forward 1413 ...

Page 1415: ...ling surfaces b Apply seal packing to the timing chain cover as shown in the illustration Seal packing Part No 08826 00100 or equivalent S Install a nozzle that has been cut to a 1 5 mm 0 16 0 20 in opening HINT Avoid applying an excessive amount to the surface S Parts must be assembled within 3 minutes of ap plication Otherwise the material must be removed and reapplied S Immediately remove nozzl...

Page 1416: ...m 10 ft lbf for D and E 11 N m 113 kgf cm 8 ft lbf for B 12 mm head 18 5 N m 189 kgf cm 14 ft lbf for A NOTICE S Pay attention not to wrap the chain and slipper over the chain cover seal line S After installing the chain cover must install the mounting bracket and water pump within 15 minutes HINT Each bolt length in indicated in the illustration A 45 mm 1 77 in B 35 mm 1 38 in C 22 mm 0 87 in D 2...

Page 1417: ...wn in the illustration Seal packing Part No 08826 00100 or equivalent S Install a nozzle that has been cut to a 1 5 mm open ing HINT Avoid applying an excessive amount to the surface S Parts must be assembled within 3 minutes of ap plication Otherwise the material must be removed and reapplied S Immediately remove nozzle from the tube and rein stall cap c Install the 2 gasket to the timing chain c...

Page 1418: ...olt Torque 9 3 N m 95 kgf cm 82 in lbf 9 2ZZ GE INSTALL EXHAUST MANIFOLD See page EM 67 10 2ZZ GE INSTALL EXHAUST MANIFOLD STAY See page EM 67 11 2ZZ GE INSTALL FRONT EXHAUST PIPE See page EM 67 12 1ZZ FE INSTALL RH ENGINE MOUNTING BRACKET a Apply seal packing to threads of the mounting bolt Seal packing Part No 08826 00080 or equivalent HINT Do not apply seal packing to 2 or 3 threads of the bolt...

Page 1419: ...y with the key groove of the pulley and slide on the pulley c Using SST install the pulley bolt SST 09960 10010 09962 01000 09963 01000 Torque 1ZZ FE 138 N m 1 409 kgf cm 102 ft lbf 2ZZ GE 120 N m 1 224 kgf cm 89 ft lbf 17 INSTALL CHAIN TENSIONER a Check the chain tensioner See page EM 16 b Release the ratchet pawl fully push in the plunger and ap ply the hook to the pin so that the plunger cannot...

Page 1420: ...plunger HINT If the plunger does not spring out press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out 19 CHECK VALVE TIMING a Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover NOTICE Always turn the crankshaft clockwise b Check that the point marks of the ca...

Page 1421: ...applied d Install the cylinder head cover with the 9 bolts 2 seal washers and 2 nuts Uniformly tighten the bolts and nuts in the several passes in the sequence shown Torque w o washer 11 N m 113 kgf cm 8 ft lbf w washer 9 0 N m 92 kgf cm 80 in lbf e Connect the 2 PCV hoses to the cylinder head cover f Install the ignition coil See page IG 7 21 2ZZ GE INSTALL CYLINDER HEAD COVER a Remove any old pa...

Page 1422: ...Nut 10 N m 100 kgf cm 7 ft lbf Bolt 25 N m 255 kgf cm 18 ft lbf h Connect the No 3 ventilation hose to the No 1 ventilation pipe i Install the ignition coil See page IG 7 22 INSTALL RH ENGINE MOUNTING INSULATOR a 1ZZ FE Install the RH engine mounting insulator with the 4 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf b 2ZZ GE Install the RH engine mounting insulator with the 5 bolts and 2 nut...

Page 1423: ... MECHANICAL TIMING CHAIN EM 37 2005 CELICA RM1131U 28 FILL WITH ENGINE COOLANT See page CO 2 29 INSTALL FRONT FENDER APRON SEAL AND UPPER RADIATOR SUPPORT SEAL 30 START ENGINE AND CHECK FOR COOLANT LEAKS 1422 ...

Page 1424: ...E RH Engine Mounting Insulator 52 530 38 2ZZ GE RH Engine Mounting Insulator 52 530 38 52 530 38 RH Engine Under Cover z Gasket zGasket 43 440 32 Front Exhaust Pipe O Ring O Ring N m kgf cm ft lbf Specified torque Non reusable part z 52 530 38 52 530 38 43 440 32 43 440 32 2ZZ GE Air Switching Valve 52 530 38 EM 38 ENGINE MECHANICAL CYLINDER HEAD 2005 CELICA RM1131U CYLINDER HEAD COMPONENTS 1423 ...

Page 1425: ...l Tube Assembly Spacer z O Ring Injector z Grommet Injector Connector Accelerator Control Cable Bracket Throttle Position Sensor Connector PCV Hose Water Bypass Hose IAC Valve Connector Throttle Body Brake Booster Vacuum Hose z Gasket Oil Control Valve for VVT Oil Filter z Gasket Intake Manifold N m kgf cm ft lbf Specified torque Non reusable part z 30 306 22 Lower Heated Insulator 49 500 37 30 30...

Page 1426: ...ve PCV Hose z Gasket Camshaft Position Sensor Spacer O Ring Injector zGrommet Injector Connector Throttle Position Sensor Connector Water Bypass Hose Throttle Body zGasket Intake Manifold Stay 46 469 34 34 347 25 Intake Manifold Insulator Generator Bracket Intake Manifold N m kgf cm ft lbf Specified torque zNon reusable part z PCV Hose Throttle Bracket 20 204 15 20 204 15 50 510 37 50 510 37 24 24...

Page 1427: ...g Chain Chain Tensioner Slipper Chain Tensioner Upper Radiator Hose Cylinder Head Gasket z Crank Angle Sensor Plate Chain Vibration Damper Crankshaft Position Sensor zO Ring 9 0 92 80 in lbf Timing Chain Cover Crankshaft Front Oil Seal z Crankshaft Pulley 138 1 400 102 x6 Water Pump N m kgf cm ft lbf Specified torque zNon reusable part Valve Lifter Keeper Spring Retainer Valve Spring Oil Seal z Sp...

Page 1428: ...20 74 Cylinder Head x 10 9 0 92 80 in lbf Chain Tensioner Timing Chain Cover Timing Chain Chain Tensioner Slipper z Gasket zCylinder Head Gasket zGasket Crankshaft Front Oil Seal z Crankshaft Pulley 120 1 224 89 Water Pump x6 Water Pump Pulley x4 z O Ring N m kgf cm ft lbf Specified torque zNon reusable part Crank Angle Sensor Plate Chain Vibration Damper Crankshaft Position Sensor 35 360 26 Turn ...

Page 1429: ...lbf Oil Filter z Gasket Oil Control Valve for VVTL Shim Keeper Spring Retainer Valve Spring Spring Seat Cylinder Head Valve Oil Filter z Gasket 29 300 22 Oil Control Valve for VVT N m kgf cm ft lbf Specified torque zNon reusable part 2ZZ GE Valve Stem Seal z ENGINE MECHANICAL CYLINDER HEAD EM 43 2005 CELICA RM1131U 1428 ...

Page 1430: ...E DRIVE BELT AND ALTERNATOR See page CH 7 9 REMOVE EXHAUST PIPE See page EM 76 10 1ZZ FE REMOVE EXHAUST MANIFOLD a Remove the 3 bolts and exhaust manifold stay b Remove the 4 bolts and upper heat insulator c Remove the 5 nuts exhaust manifold and gasket d Remove the 4 bolts and lower heat insulator 11 2ZZ GE REMOVE EXHAUST MANIFOLD a Remove the 4 bolts and exhaust manifold stay b Remove the 5 bolt...

Page 1431: ...nnect the 2 clamps and engine wire protector from the intake manifold 18 2ZZ GE DISCONNECT ENGINE WIRE FROM CYLINDER HEAD a Disconnect the ECT sensor connector b Disconnect the camshaft position sensor connector c Disconnect the oil control valve for VVT connectors d Disconnect the oil control valve for VVTL connectors e Disconnect the oil pressure switch connector f Disconnect the 2 ground wires ...

Page 1432: ...intake manifold and gasket f Remove the intake manifold insulator 21 REMOVE CAMSHAFT POSITION SENSOR 22 REMOVE ECT SENSOR 23 REMOVE PCV VALVE AND GROMMET 24 REMOVE OIL FILLER CAP 25 REMOVE CAMSHAFT TIMING SPROCKETS See page IG 9 26 1ZZ FE REMOVE CAMSHAFT Uniformly loosen and remove the 19 bearing cap bolts in sever al passes in the sequence shown and remove the 9 bearing caps intake and exhaust ca...

Page 1433: ...passes in the sequence shown Remove the 10 cylinder head bolts and plate washers NOTICE Head warpage or cracking could result from removing bolts in an incorrect order d Remove the bolt holding the water bypass pipe to the cyl inder head e Lift the cylinder from the dowels on the cylinder block and replace the cylinder head on wooden blocks on a bench HINT If the cylinder head is difficult to lift...

Page 1434: ...essure switch SST 09816 30010 c Remove the 3 bolts 2 nuts oil control valve housing and gasket d Remove the oil control valve filter 4 2ZZ GE REMOVE VALVE ROCKER ARM a Remove the 2 bolts rocker No 1 and No 2 shafts b Remove the 8 valve rocker arms HINT Arrange the rocker arms in the correct order 5 REMOVE VALVE LIFTERS HINT Arrange the valve lifters in the correct order 6 REMOVE VALVES a Using SST...

Page 1435: ...CAL CYLINDER HEAD EM 49 2005 CELICA RM1131U f Using compressed air and magnetic finger remove the spring seat by blowing air HINT Arrange the valves valve springs spring seats and spring re tainers in the correct order 1434 ...

Page 1436: ...urface c Using compressed air blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high pressure compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket materials from the cylinder block contact surface NOTICE Be careful not to scratch the cylinder block contact sur face 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from t...

Page 1437: ...edge and feeler gauge measure the surface contacting the cylinder block and the manifolds for war page Maximum warpage 0 05 mm 0 0020 in If warpage is greater than maximum replace the cylinder head 7 INSPECT FOR CRACKS Using a dye penetrate check the combustion chamber intake ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head 8 CLEAN VALVES a Using a gas...

Page 1438: ...Exhaust 5 445 5 470 mm 0 21437 0 21535 in c Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance 1ZZ FE Intake 0 025 0 060 mm 0 0010 0 0024 in Exhaust 0 030 0 065 mm 0 0012 0 0026 in 2ZZ GE Intake 0 025 0 058 mm 0 00098 0 00228 in Exhaust 0 030 0 063 mm 0 00118 0 00248 in Maximum oil clearance 1ZZ FE Intake 0 08 mm 0 0031 in Exhaust...

Page 1439: ...11 3 mm 4 382 in If the overall length is less than minimum replace the valve e Check the surface of the valve stem tip for wear If the valve stem tip is worn replace the valve 11 INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b After resurfacing the valve seat 45 measure the residu ary width of the valve seat 45 Mini...

Page 1440: ...f not correct the valve seats as follows 1 If the seating is too high on the valve face use 30 and 45 cutters to correct the seat 2 If the seating is too low on the valve face use 75 and 45 cutters to correct the seat e Hand lap the valve and valve seat with an abrasive com pound f After hand lapping clean the valve and valve seat 12 INSPECT VALVE SPRINGS a Using a steel square measure the deviati...

Page 1441: ... kgf 49 6 55 5 lbf at 38 5 mm 1 516 in Exhaust 208 2 229 8 N 21 2 23 4 kgf 47 6 52 6 lbf at 38 5 mm 1 516 in Maximum working tension 1ZZ FE 244 9 276 1 N 25 5 28 1 kgf 56 2 61 9 lbf at 24 6 mm 0 969 in 2ZZ GE Intake 533 589 N 54 4 60 1 kgf 119 9 132 5 lbf at 27 3 mm 1 075 in Exhaust 495 5 548 5 N 50 5 55 9 kgf 111 3 123 2 lbf at 28 5 mm 1 122 in If the installed tension is not as specified replace...

Page 1442: ...mum cam lobe height 1ZZ FE Intake 44 18 mm 1 7394 in Exhaust 43 61 mm 1 7169 in 2ZZ GE Intake No 1 40 45 mm 1 5925 in No 2 38 61 mm 1 5201 in Exhaust No 1 39 86 mm 1 5693 No 2 38 71 mm 1 5240 If the cam lobe height is less than minimum replace the cam shaft 15 INSPECT CAMSHAFT JOURNALS Using a micrometer measure the journal diameter 1ZZ FE No 1 journal diameter 34 449 34 465 mm 1 3563 1 3569 in Ot...

Page 1443: ...bf 2ZZ GE 18 5 N m 189 kgf cm 14 ft lbf NOTICE Do not turn the camshaft e Remove the bearing caps f Measure the plastigage at its widest point 1ZZ FE Standard oil clearance 0 035 0 072 mm 0 0014 0 0028 in Maximum oil clearance 0 10 mm 0 0039 in 2ZZ GE Standard oil clearance No 1 journal 0 035 0 076 mm 0 00138 0 00299 in Other journal 0 035 0 072 mm 0 00138 0 00283 in Maximum oil clearance 0 10 mm ...

Page 1444: ... head as a set c Remove the camshafts 18 INSPECT VALVE TIMING CONTROLLER ASSEMBLY a Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration NOTICE Do not apply tape in the range from the tip of the camshaft to 18 mm from that tip b Install the valve timing controller assembly Torque 47 N m 480 kgf cm 35 ft lbf NOTICE Do not push valve timing controller assembly ...

Page 1445: ...he valve timing controller assembly turn back and forth and check the movable range and that there is no disturbance Standard Movable smoothly in the range about 30 g Turn the valve timing controller assembly with your hand and lock it at the maximum delay angel position 19 1ZZ FE INSPECT VALVE LIFTERS AND LIFTER BORES a Using a caliper gauge measure the lifter bore diameter of the cylinder head L...

Page 1446: ... is greater than maximum replace the manifold 21 INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge measure the surface contacting the cylinder head for warpage Maximum warpage 0 70 mm 0 0276 in If warpage is greater than maximum replace the manifold 22 INSPECT CYLINDER HEAD BOLTS Standard outside diameter 9 0 9 2 mm 0 354 0 362 in Minimum outside diameter 9 0 mm 0 354 in If...

Page 1447: ... hammer tap out the guide bushing SST 09201 01055 09950 70010 09951 07100 c Using a caliper gauge measure the bushing bore diame ter of the cylinder head d 1ZZ FE Select the new guide bushing STD or O S 0 05 If the bushing bore diameter of the cylinder head is greater than 10 306 mm 0 4057 in machine the bushing bore to the fol lowing dimension 10 335 10 356 mm 0 4068 0 4077 in If the bushing bore...

Page 1448: ...owing dimension 10 538 10 556 mm 0 4149 0 4156 in If the bushing bore diameter of the cylinder head is greater than 10 556 mm 0 4156 in replace the cylinder head g 2ZZ GE Gradually heat the cylinder head to 110 130 C 230 266 F h Using SST and a hammer tap in a new guide bushing to the specified protrusion height SST 09201 01055 09950 70010 09951 07100 Protrusion height 1ZZ FE 8 7 9 1 mm 0 342 0 35...

Page 1449: ...o be assembled S Before installing the parts apply fresh engine oil to all slid ing and rotating surfaces S Replace oil seals with new ones 1 INSTALL WATER HOSE UNIONS HINT When using a new cylinder head water hose unions must be installed a Mark the standard position away from the edge onto the water hose union b Apply adhesive to the water hose union hole of the cylin der head Adhesive Part No 0...

Page 1450: ...618 in C 24 mm 0 95 in D 69 8 mm 2 630 in NOTICE Avoid pressing a new water hose union in too far by mea suring the amount of protrusion while pressing 2 INSTALL VALVES a Install the spring seat b Using SST push in a new oil seal SST 09201 41020 HINT S 1ZZ FE The intake valve oil seal is light brown and the exhaust valve oil seal is gray S 2ZZ GE The intake valve oil seal is black and the exhaust ...

Page 1451: ... careful not to damage the valve stem tip 3 INSTALL VALVE LIFTERS a Install the valve lifter b Check that the valve lifter rotates smoothly by hand 4 2ZZ GE INSTALL VALVE ROCKER ARM a Set the 8 valve rocker arms b Install the rocker No 1 and No 2 shaft with the 2 bolts Torque 7 5 N m 76 kgf cm 66 in lbf HINT S Position the slit of the locker shaft in the direction shown in the illustration S Align...

Page 1452: ...r equivalent d Using SST install the oil pressure switch SST 09816 30010 Torque 13 N m 130 kgf cm 9 ft lbf e Install the oil control valve for VVTL with the bolt 6 INSTALL CONTROL VALVE for VVT Install the oil control valve for VVT with the bolt 7 INSTALL OIL CONTROL VALVE FILTER Install the oil control valve filter and new gasket with the bolt Torque 29 N m 300 kgf cm 22 ft lbf 1451 ...

Page 1453: ...e bottom part of the head 2 INSTALL CYLINDER HEAD BOLTS HINT S The cylinder head bolts are tightened in 2 progressive steps steps b and d S If any cylinder head bolt is broken or deformed replace it a Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts b Using a 10 mm bi hexagon wrench install and uniformly tighten the 10 cylinder head bolts and plate was...

Page 1454: ...to the water hose unions 3 INSTALL CAMSHAFTS a Place the 2 camshafts on the cylinder head with the No 1 cam lobes facing as shown the illustration b Install the bearing caps in their proper locations HINT S 1ZZ FE No 3 camshaft bearing cap has a number and front mark S 2ZZ GE No 2 No 3 camshaft bearing cap has a number and front mark c Apply a light coat of engine oil on the threads and under the ...

Page 1455: ...SITION SENSOR See page IG 10 10 1ZZ FE INSTALL INTAKE MANIFOLD a Install a new gasket 2 wire harness stays and the intake manifold with the 4 bolts and 2 nuts Torque 30 N m 306 kgf cm 22 ft lbf b Connect the brake booster vacuum hose c Connect the EVAP hose for ORVR 11 2ZZ GE INSTALL INTAKE MANIFOLD a Install the intake manifold insulator to the cylinder block b Install a new gasket and the intake...

Page 1456: ...ntrol valve for VVTL connector f Connect the camshaft position sensor connector g Connect the ECT sensor connector h Install the accelerator cable bracket with the 2 bolts 14 INSTALL INJECTORS See page SF 24 15 INSTALL THROTTLE BODY See page SF 38 or SF 44 16 INSTAL PCV HOSES 17 INSTALL SPARK PLUGS See page IG 1 18 INSTALL IGNITION COIL See page IG 7 19 1ZZ FE INSTALL EXHAUST MANIFOLD a Install th...

Page 1457: ...eat insulator with the 4 bolts Torque 20 N m 204 kgf cm 15 ft lbf d Install the exhaust manifold stay with the 3 bolts Torque 50 N m 510 kgf cm 37 ft lbf 21 INSTALL EXHAUST PIPE See page EM 82 22 INSTALL GENERATOR AND DRIVE BELT See page CH 17 23 2ZZ GE INSTALL AIR SWITCHING VALVE See page EC 18 24 1ZZ FE CONNECT ACCELERATOR CABLE 25 INSTALL AIR CLEANER ASSEMBLY 26 INSTALL ECM BOX See page EM 82 2...

Page 1458: ...ECM Box Stay VSV for EVAP Air Cleaner Cap Air Filter Air Cleaner Case LH Engine Under Cover N m kgf cm ft lbf Specified torque 18 185 13 12 120 9 6 9 70 61 in lbf 6 9 70 61 in lbf 5 0 51 44 in lbf 2ZZ GE Air Switching Valve 2ZZ GE Air Pump Assembly 1ZZ FE Cruise Control Accumulator EM 72 ENGINE MECHANICAL ENGINE UNIT 2005 CELICA RM1131U ENGINE UNIT COMPONENTS 1457 ...

Page 1459: ...enerator Engine Coolant Reservoir Radiator Assembly Radiator Upper Support Hood Lock Center Brace J B Cover J B Bumper Cover N m kgf cm ft lbf Specified torque Condenser Upper Support 25 255 18 ENGINE MECHANICAL ENGINE UNIT EM 73 2005 CELICA RM1131U 1458 ...

Page 1460: ...653 47 87 887 64 64 653 47 RH Drive Shaft z Snap Ring z Snap Ring LH Drive Shaft z z Gasket 43 440 32 O Ring zGasket Front Exhaust Pipe N m kgf cm ft lbf Specified torque zNon reusable part 45 460 33 52 530 38 52 530 38 52 530 38 43 440 32 43 440 32 39 400 29 157 1 600 116 157 1 600 116 EM 74 ENGINE MECHANICAL ENGINE UNIT 2005 CELICA RM1131U 1459 ...

Page 1461: ...tay 2ZZ GE Lower Heated Insulator 1ZZ FE Exhaust Manifold Stay z Gasket 1ZZ FE 1ZZ FE RH Engine Mounting Insulator M T Transmission Control Cable A T Transmission Control Cable 2ZZ GE zGasket 2ZZ GE RH Engine Mounting Insulator 80 816 59 Clutch Release Cylinder N m kgf cm ft lbf Specified torque zNon reusable part 18 184 13 52 530 38 52 530 38 12 123 9 12 123 9 4 9 50 43 in lbf 49 500 37 50 510 37...

Page 1462: ...disconnect the air cleaner cap from the air cleaner case e Loosen the hose clamp and disconnect the air cleaner hose from the throttle body 11 REMOVE AIR CLEANER CASE a Remove the air filter b Disconnect the hose from the VSV for Canister Closed VALVE CVC c Disconnect the hose from the intake air control valve d Remove the 2 bolts and disconnect the air cleaner case e Disconnect the 2 hoses from t...

Page 1463: ...ne wire from the relay box 14 w Cruise Control System DISCONNECT CRUISE CONTROL ACTUATOR a Disconnect the actuator connector b Remove the 3 bolts and disconnect the actuator from the body 15 REMOVE RADIATOR ASSEMBLY See page CO 17 16 REMOVE DRIVE BELT AND GENERATOR See page CH 7 17 w A C DISCONNECT A C COMPRESSOR a Disconnect the A C compressor connector b Remove the 3 bolts and disconnect the A C...

Page 1464: ...ts and disconnect the release cylinder from the transaxle 20 DISCONNECT TRANSAXLE CONTROL CABLE S 21 DISCONNECT 2 GROUND CABLES 22 REMOVE DRIVE SHAFT See page SA 21 23 REMOVE EXHAUST PIPE a Disconnect the 2 heated oxygen sensors b Remove the 4 bolts and springs c Disconnect the 2 O rings and remove the exhaust pipe and 2 gaskets 24 1ZZ FE REMOVE EXHAUST MANIFOLD a Remove the 4 bolts and upper heat...

Page 1465: ...s and through bolts and disconnect the PS pump from the engine See page SR 26 HINT Put aside the pump and suspend it to the cowl with a string 27 REMOVE STABILIZER BAR BRACKET See page SA 52 28 DISCONNECT PS GEAR Remove the 4 bolts and disconnect the PS gear from the sus pension member HINT Suspend the PS gear securely 29 REMOVE SUSPENSION MEMBER Remove the 9 bolts 3 nuts and suspension member 30 ...

Page 1466: ...28 ft lbf d Attach the engine sling device to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 31 REMOVE REAR ENGINE MOUNTING a Remove the through bolt and rear engine mounting insu lator b Remove the 3 bolts and rear engine mounting bracket 32 REMOVE ENGINE AND TRANSAXLE ASSEMBLY a Remove the LH engine mounting through bolt and nut b 1ZZ FE Remov...

Page 1467: ... slowly and carefully and raise the vehicle HINT Make sure the engine is clear of all wiring hoses and cables e Place the engine and transaxle assembly onto the stand 33 SEPARATE ENGINE AND TRANSAXLE C56 M T See page MX 4 C60 M T See page MX 4 U240E A T See page AX 31 U341E A T See page AX 31 1466 ...

Page 1468: ...eep the engine level and align RH and LH mountings with the body bracket d 1ZZ FE Install the RH engine mounting insulator with the 4 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf e 2ZZ GE Install the RH engine mounting insulator with the 5 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf f Install the LH engine mounting through bolt and nut Torque 80 N m 816 kgf cm 59 ft lbf 3 REMOVE ENG...

Page 1469: ... STABILIZER BAR BRACKET See page SA 54 8 CONNECT PS PUMP a Install the PS pump with the 2 through bolts and nuts See page SR 34 Torque 36 N m 370 kgf cm 27 ft lbf b Connect the PS oil pressure switch connector 9 1ZZ FE INSTALL EXHAUST MANIFOLD a Install the gasket and exhaust manifold with the 5 nuts Torque 37 N m 377 kgf cm 27 ft lbf b Install the exhaust manifold stay with the 3 bolts Torque 49 ...

Page 1470: ...heated oxygen sensors See page EM 117 12 INSTALL DRIVE SHAFT See page SA 33 13 CONNECT 2 GROUND CABLES 14 CONNECT TRANSAXLE CONTROL CABLE S 15 M T CONNECT CLUTCH RELEASE CYLINDER a Install the release cylinder with the 2 bolts Torque 12 N m 120 kgf cm 9 ft lbf b Install the brackets with the 3 bolts Torque Bolt A 12 N m 120 kgf cm 9 ft lbf Bolt B 4 9 N m 50 kgf cm 43 in lbf 16 CONNECT TUBE AND HOS...

Page 1471: ...BLY See page CO 23 20 w Cruise Control System INSTALL CRUISE CONTROL ACTUATOR a Install the actuator with the 3 bolts b Connect the actuator connector 21 CONNECT ENGINE WIRE TO ENGINE COMPART MENT RELAY BOX a Install the engine wire to the relay box b Connect the 3 connectors c Connect the J B to the relay box d Connect the 3 connectors e Install the relay box upper cover 22 INSTALL ECM BOX a Inst...

Page 1472: ...r canister closed valve CVC e Install the air filter 24 INSTALL AIR CLEANER CAP a Install the air cleaner hose to the throttle body with the hose clamp b Connect the air cleaner cap to the air cleaner case with the 3 clamps c Connect the 2 hoses d Connect the VSV for EVAP e Connect the MAF meter connector 25 2ZZ GE INSTALL AIR PUMP ASSEMBLY See page EC 18 26 2ZZ GE INSTALL AIR SWITCHING VALVE See ...

Page 1473: ... 92 80 in lbf Oil Guide and Oil Dipstick z O Ring Engine Coolant Drain Union 20 200 14 Knock Sensor 44 450 33 z Gasket Water Inlet Thermostat Oil Pump zGasket x 5 N m kgf cm ft lbf Specified torque zNon reusable part ENGINE MECHANICAL CYLINDER BLOCK EM 87 2005 CELICA RM1131U CYLINDER BLOCK COMPONENTS 1472 ...

Page 1474: ...lant Drain Union 25 255 18 Knock Sensor No 3 Ventilation Hose z Gasket Ventilation Case zGasket Thermostat Water Inlet Oil Pump zGasket x 5 2ZZ GE N m kgf cm ft lbf Specified torque z Non reusable part 20 204 15 EM 88 ENGINE MECHANICAL CYLINDER BLOCK 2005 CELICA RM1131U 1473 ...

Page 1475: ...ust Washer Crankshaft Bearing Cap Sub Assembly z Gasket Side Rail z Snap Ring Crankshaft Thrust Washer Oil Filter Union Oil Filter Oil Pan z Gasket Oil Strainer 9 92 80 in lbf x14 9 92 80 in lbf 37 378 27 Piston Pin 30 306 21 18 5 189 13 N m kgf cm ft lbf Specified torque zNon reusable part See page EM 108 1st 20 200 15 2nd Turn 90 1st 22 225 16 2nd 44 449 32 3rd Turn 45 See page EM 108 4rd Turn 4...

Page 1476: ...aft Thrust Washer z Crankshaft Rear Oil Seal Lower Main Bearing Upper Main Bearing Crankshaft Thrust Washer Crankshaft Oil Pan Baffle 9 0 92 80 in lbf Bearing Cap Assembly z Gasket 18 185 13 43 438 32 Oil Filter Union Oil Filter 9 0 92 80 in lbf 37 378 27 Oil Strainer z Gasket Oil Pan 9 0 92 80 in lbf 1st 22 225 16 2nd 44 449 32 3rd Turn 45 See page EM 108 4rd Turn 45 N m kgf cm ft lbf Specified t...

Page 1477: ...YLINDER HEAD See page EM 44 7 1ZZ FE REMOVE OIL DIPSTICK AND GUIDE a Remove the bolt and oil dipstick and guide b Remove the O ring from the dipstick 8 REMOVE WATER BYPASS PIPE Remove the 2 nuts bolts and water bypass pipe 9 REMOVE THERMOSTAT See page CO 9 10 REMOVE KNOCK SENSOR 11 REMOVE ENGINE COOLANT DRAIN UNION 12 REMOVE OIL PUMP See page LU 9 13 2ZZ GE REMOVE VENTILATION CASE a Remove the 3 n...

Page 1478: ... and 4 nuts c Insert the blade of SST between the bearing cap sub as sembly and oil pan and cut off applied sealer and remove the oil pan SST 09032 00101 NOTICE S Be careful not to the damage the oil pan contact sur face of the bearing cap sub assembly S Be careful not to damage the oil pan flange 17 1ZZ FE REMOVE OIL STRAINER Remove the 2 nuts bolt oil strainer and gasket 18 2ZZ GE REMOVE OIL STR...

Page 1479: ...t Connecting rod thickness 19 788 19 840 mm 0 7791 0 7811 in 20 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly b Remove the 2 connecting rod cap bolts c Using the 2 removed connecting rod cap bolts remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left HINT K...

Page 1480: ...06 kgf cm 22 ft lbf 2nd Turn extra 90 NOTICE Do not turn the crankshaft h Remove the 2 bolts connecting rod cap and lower bear ing See procedure b and c above i Measure the Plastigage at its widest point Standard oil clearance 1ZZ FE 0 028 0 060 mm 0 0011 0 0024 in 2ZZ GE 0 028 0 052 mm 0 0011 0 0020 in Maximum oil clearance 0 08 mm 0 0031 in If the oil clearance is greater than maximum replace th...

Page 1481: ... 1 494 0 0587 0 0588 j Completely remove the Plastigage 21 REMOVE PISTON AND CONNECTING ROD ASSEMBLIES a Using a ridge reamer remove all the carbon from the top of the cylinder b Push the piston connecting rod assembly and upper bearing through the top of the cylinder block HINT S Keep the bearings connecting rod and cap together S Arrange the piston and connecting rod assemblies in the correct or...

Page 1482: ...cylinder block g Clean each main journal and bearing h Check each main journal and bearing for pitting and scratches If the journal or bearing is damaged replace the bearings If necessary replace the crankshaft i Place the crankshaft on the cylinder block j Lay a strip of Plastigage across each journal k Install the bearing cap sub assembly See page EM 108 NOTICE Do not turn the crankshaft l Remov...

Page 1483: ... 2 3 3 3 4 4 0 1 2 3 4 5 6 3 3 4 4 4 5 ENGINE MECHANICAL CYLINDER BLOCK EM 97 2005 CELICA RM1131U n 1ZZ FE If using a standard bearing replace it with one having the same number If the number of the bearing cannot be de termined select the correct bearing by adding together the numbers imprinted on the cylinder block and crank shaft then selecting the bearing with the same number as the total Ther...

Page 1484: ... 1 999 2 002 0 0787 0 0788 2 002 2 005 0 0788 0 0789 2ZZ GE Standard bearing center wall thickness 1 2 3 4 5 1 989 1 992 0 0783 0 0784 1 992 1 995 0 0784 0 0785 1 995 1 998 0 0785 0 0787 1 998 2 001 0 0787 0 0788 2 001 2 004 0 0788 0 0789 p Completely remove the Plastigage 23 CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator measure the thrust clearance while prying the crankshaft back and ...

Page 1485: ...move the 2 side rails and oil ring by hand HINT Arrange the piston rings in the correct order only 27 DISCONNECT CONNECTING ROD FROM PISTON a Using a small screwdriver pry out the 2 snap rings b 1ZZ FE Gradually heat the piston to 80 90 C 176 194 F c 1ZZ FE Using a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod HINT S The piston and pin are a matche...

Page 1486: ... temperatures the cylinder liner sticks out beyond the cylinder block so always wash the cylinder block at a temperature of 45 C 133 F or less 3 INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge measure the surface contacting the cylinder head gasket for warpage Maximum warpage 0 05 mm 0 0020 in If warpage is greater than maximum replace the cylind...

Page 1487: ...Z FE 79 13 mm 3 1153 in 2ZZ GE 82 13 mm 3 2335 in Difference limit 0 10 mm 0 0039 in If the average diameter of 4 position is greater than maximum replace the cylinder block 6 REMOVE CYLINDER RIDGE If the wear is less than 0 2 mm 0 008 in using a ridge reamer grind the top of the cylinder 7 INSPECT 12 POINTED HEAD BEARING CAP SUB AS SEMBLY BOLTS Using vernier calipers measure the tension portion d...

Page 1488: ...ng a micrometer measure the piston diameter at right angles to the piston pin center line 12 0 mm 0 048 in from the piston bottom Piston diameter 1ZZ FE 78 925 78 935 mm 3 1073 3 1077 in 2ZZ GE 81 975 81 993 mm 3 2274 3 2281 in c Measure the cylinder bore diameter in the thrust direc tions See procedure in step 5 d Subtract the piston diameter measurement from the cylin der bore diameter measureme...

Page 1489: ...nd gap Standard end gap No 1 0 25 0 35 mm 0 0098 0 0138 in No 2 0 35 0 50 mm 0 0138 0 0197 in Oil Side rail 0 15 0 40 mm 0 0059 0 0157 in Maximum end gap No 1 1 05 mm 0 0413 in No 2 1 20 mm 0 0472 in Oil Side rail 1 05 mm 0 0413 in If the end gap is greater than maximum replace the piston ring If the end gap is greater than maximum even with a new piston ring replace the cylinder block 12 INSPECT ...

Page 1490: ...e inside diameter of the piston bushing Bushing inside diameter 20 013 20 025 mm 0 7879 0 7884 in c Using a micrometer measure the piston pin diameter Piston pin diameter 1ZZ FE 20 004 20 013 mm 0 7876 0 7879 in 2ZZ GE 20 004 20 016 mm 0 7876 0 7880 in d Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oil clearance 1ZZ FE 0 005 0 011 mm 0 0002 0 0...

Page 1491: ...e runout 0 03 mm 0 0012 in If the circle runout is greater than maximum replace the crank shaft 17 INSPECT MAIN JOURNALS AND CRANK PINS a Using a micrometer measure the diameter of each main journal and crank pin Main journal diameter 47 988 48 000 mm 1 8893 1 8898 in Crank pin diameter 1ZZ FE 43 992 44 000 mm 1 7320 1 7323 in 2ZZ GE 44 992 45 000 mm 1 7713 1 7717 in If the diameter is not as spec...

Page 1492: ...g SST 09222 30010 d Using a pin hole grinder hone the bushing to obtain the standard specified clearance See page EM 100 be tween the bushing and piston pin e Check the piston pin fit at normal room temperature Coat the piston pin with engine oil and push it into the connect ing rod with your thumb 2 REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal is installed to cylinder block a Using a knife c...

Page 1493: ...INDER BLOCK EM 107 2005 CELICA RM1131U c Apply MP grease to a new oil seal lip d Using SST and a hammer tap in the oil seal until its sur face is flush with the rear oil seal retainer edge SST 09223 15030 09950 70010 09951 07100 1492 ...

Page 1494: ... Using a small screwdriver install a new snap ring at one end of the piston pin hole HINT Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston b 1ZZ FE Gradually heat the piston to 80 90 C 176 194 F c Coat the piston pin with engine oil d Align the front marks on the piston and connecting rod and push in the piston with your thumb e Using a small scre...

Page 1495: ... that the ring ends are as shown NOTICE Do not align the ring ends 3 INSTALL CONNECTING ROD BEARINGS a Align the bearing claw with the groove of the connecting rod or connecting cap b Install the bearings in the connecting rod and connecting rod cap 4 INSTALL MAIN BEARINGS HINT Upper bearings have an oil groove and oil holes Lower bear ings do not a Align the bearing claw with the claw groove of t...

Page 1496: ...ents to remove all the loose materials S Using a non reusable solvent clean both sealing surfaces b Apply seal packing to the bearing cap sub assembly as shown in the illustration Seal packing Part No 08826 00080 or equivalent S Install a nozzle that has been cut to a 1 2 mm 0 004 0 08 in opening HINT Avoid applying an excessive amount to the surface S Parts must be assembled within 3 minutes of a...

Page 1497: ...ecification replace the bearing cap sub assembly bolt d Mark the front of the bearing cap sub assembly bolts with paint e Retighten the bearing cap sub assembly bolts by 45 and 45 in the numerical order shown f Check that the painted mark is now at a 90 angle to the front 9 INSTALL HEXAGON HEAD BEARING CAP SUB AS SEMBLY BOLTS a Install and uniformly tighten the 10 bearing cap sub as sembly bolts i...

Page 1498: ...ALL CONNECTING ROD CAP BOLTS HINT S The connecting rod cap bolts are tightened in 2 progres sive steps steps b and d S If any of the connecting rod cap bolts is broken or de formed replace it a Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts b Install and alternately tighten the 2 connecting rod cap bolts in several passes Torque 1ZZ FE 20 N m 20...

Page 1499: ...ainer with the 2 nuts and bolt Torque 9 0 N m 92 kgf cm 80 in lbf 18 INSTALL OIL PAN a Remove any old packing FIPG material and be careful not to drop any oil on the contact surface of the main bear ing cap and oil pan S Using a razor blade and gasket scraper remove all the old packing FIPG material from the gasket sur faces and sealing grooves S Thoroughly clean all components to remove all the l...

Page 1500: ...s Uniformly tighten the bolts and nuts in several passes Torque 9 0 N m 92 kgf cm 80 in lbf 19 INSTALL OIL FILTER UNION Torque 30 N m 306 kgf cm 21 ft lbf 20 INSTALL OIL FILTER See page LU 3 21 INSTALL OIL PUMP See page LU 14 22 INSTALL ENGINE COOLANT DRAIN UNION a Apply adhesive to 2 or 3 threads Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent b Install the drain union Torq...

Page 1501: ...AND GUIDE a Install a new O ring on the dipstick guide b Apply soapy water on the O ring c Connect the dipstick guide end to the main bearing cap d Install the dipstick guide with the bolt Torque 11 N m 113 kgf cm 8 ft lbf 28 INSTALL CYLINDER HEAD See page EM 67 29 INSTALL ENGINE WIRE 30 INSTALL TIMING SPROCKETS AND TIMING CHAIN See page EM 26 31 REMOVE ENGINE STAND 32 M T INSTALL FLYWHEEL HINT Th...

Page 1502: ...E PLATE a Install the front spacer drive plate and rear plate on the crankshaft b Apply adhesive to 2 or 3 threads of the mounting bolt end Adhesive Part No 08833 00070 THREE BOND or equivalent c Install and uniformly tighten the 8 mounting bolts in sev eral passes in the sequence shown Torque 88 N m 897 kgf cm 65 ft lbf 1501 ...

Page 1503: ...r HINT D Before installing oxygen sensor twist sensor wire with grommet counterclockwise 3 and 1 2 turns D After installing oxygen sensor check that sensor wire is not twisted If it is twisted remove oxygen sensor and reinstall it sensor wire is not twisted If it is twisted remove oxygen sensor and reinstall it Heated Oxygen Sensor Bank1 Sensor1 Heated Oxygen Sensor Bank1 Sensor2 44 450 33 44 450 ...

Page 1504: ...ontaining HC being released from the fuel tank 2 The function of each system is shown in these table System Abbreviation Function 1 Positive Crankcase Ventilation 2 Evaporative Emission Control 3 Three way Catalytic Converter 4 Sequential Multi port Fuel Injection PCV EVAP TWC SFI Reduces HC Reduces evaporated HC Reduces HC CO and NOx Injects a precisely timed optimum amount of fuel for reduced ex...

Page 1505: ...r Canister Closed Valve CCV Vapor Pressure Sensor Vent Line VSV for Pressure Switching Valve Air Inlet Line EVAP Line Purge Line EC 2 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING 2005 CELICA RM1131U PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION 1504 ...

Page 1506: ...ce Port Fuel Tank Cap EVAP Line Vent Line Air Inlet Line Air Drain Hose Filler Pipe VSV for Canister Closed Valve CCV VSV for Pressure Switching Valve 2ZZ GE Pressure Sensor 2ZZ GE Air Pump Assembly Air Filter 2ZZ GE Air Switching Valve 2ZZ GE Check Valve 2ZZ GE VSV for Air Switching Valve EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRAWING EC 3 2005 CELICA RM1131U DRAWING 1505 ...

Page 1507: ... valve 2 INSTALL CLEAN HOSE TO PCV VALVE 3 INSPECT PCV VALVE OPERATION a Blow air into the cylinder head side and check that air passes through easily CAUTION Do not suck air through the valve Petroleum substances inside the valve are harmful b Blow air into the intake manifold side and check that air passes through with difficulty If operation is not as specified replace the PCV valve 4 REMOVE CL...

Page 1508: ...urge Line Hose N m kgf cm ft lbf Air Drain Hose EVAP Line Hose Tail Pipe Heated Insulator Charcoal Canister 18 184 13 5 5 56 49 in lbf 5 5 56 49 in lbf EMISSION CONTROL EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 2005 CELICA RM1131U EVAPORATIVE EMISSION EVAP CONTROL SYSTEM COMPONENTS 1507 ...

Page 1509: ...INSPECT EVAP SYSTEM LINE a Warm up the engine and stop the engine Allow the engine to warm up to normal operating tempera ture b Install a vacuum gauge EVAP control system test equip ment vacuum gauge to the EVAP service port on the purge line c TOYOTA hand held tester Forced driving of the VSV for the EVAP 1 Connect a TOYOTA hand held tester to the DLC3 2 Start the engine 3 Push the TOYOTA hand h...

Page 1510: ...TA hand held tester Conclude forced driving of the VSV for the EVAP 1 Stop the engine 2 Disconnect the positive and negative leads from the battery and from the VSV terminals for the EVAP 3 Connect the VSV connector for the EVAP h Disconnect the vacuum gauge from the EVAP service port on the purge line i Connect a pressure gauge to the EVAP service port on the purge line j Check the pressure 1 Clo...

Page 1511: ...al pressure of the fuel tank can be held for 1 minute d Check the connected portions of each hose and pipe e Check the installed parts on the fuel tank If there is no abnormality replace the fuel tank and filler pipe f Reconnect the EVAP line hose to the charcoal canister 7 INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE a Disconnect the purge line hose and EVAP line hose from the charcoal canister...

Page 1512: ...t the purge line hose EVAP line hose and air inlet line hose from the charcoal canister c Disconnect the vent line hose from charcoal canister 1 Push the connector deep inside 2 Pinch portion A 3 Pull out the connector d Remove the 3 nuts and charcoal canister assembly 10 INSPECT CHARCOAL CANISTER a Visually check the charcoal canister for cracks or dam age HINT Be sure to check the areas indicate...

Page 1513: ...um 3 43 kPa 25 7 mmHg 1 01 in Hg to the purge port check that the vacuum does not decrease when the air inlet port is closed and check that the vacuum decreases when the air inlet port is released 5 While holding the air inlet port closed apply vacuum 3 43 kPa 25 7 mmHg 1 01 in Hg to the EVAP port and check that air flows into the purge port If a problem is found replace the charcoal canister 6 Re...

Page 1514: ...If any port of the heat insulator is damaged or dented to the extent that it contacts the three way catalytic converter repair or replace it 2 CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3 CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS CRACKS OR DAMAGE 4 CHECK HEAT INSULATOR FOR DAMAGE 5 CHECK FOR ADEQUATE CLEARANCE BETWEEN EXHAUST SYSTEM AND HEAT INSULATOR ON THE BODY 1513 ...

Page 1515: ...BLY a Using a plier grip the claws of the hose clip and slide the clip along the air hose b Disconnect the air hose c Disconnect the air pump connector Test conditions S Water temperature 15 C 45 C 5 F 113 F S Engine running Below 7 100 rpm S Battery voltage Above 10 5 V S DTC No displayed d Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 than check tha...

Page 1516: ...sing an ohmmeter check that there is no continuity between each termianl and the body If there is continuity replace the VSV 8 INSPECT VSV OPERATION a Check that air flows from ports E to G b Apply battery positive voltage across the terminals c Check that air flows from ports E to F If operation is not as specified replace the VSV 1515 ...

Page 1517: ...sor Clip Bracket Vacuum Hose zNon reusable part z Air Pump Assembly Air Pump Relay Bush Pressure Sensor Connector N m kgf cm ft lbf Specified torque 8 0 82 71 in lbf 8 0 82 71 in lbf 6 0 61 53 in lbf VSV 5 0 55 48 in lbf 20 5 209 15 EC 14 EMISSION CONTROL SECONDARY AIR INJECTION SYSTEM 2ZZ GE 2005 CELICA RM1131U COMPONENTS 1516 ...

Page 1518: ...e sensor connector b Using a plier grip the claws of the hose clips and slide the clips along the hoses c Disconnect the 2 air hoses d Disconnect the vacuum hoses e Remove the 2 bolts and air switching valve Torque 20 5 N m 209 kgf cm 15 ft lbf f Remove the 2 bolts and bracket Torque 8 0 N m 82 kgf cm 71 in lbf g Remove the 2 bushes 4 REMOVE PRESSURE SENSOR a Remove the vacuum hose b Remove the 2 ...

Page 1519: ...ove the bolt and disconnect the ground cable c Disconnect the connectors d Disconnect the vacuum hose from the F port of VSV e Remove the 4 bolts and air pump assembly Torque 8 0 N m 82 kgf cm 71 in lbf 6 REMOVE VSV a Disconnect the 2 vacuum hoses b Remove the bolt and VSV 7 REMOVE AIR PUMP RELAY a Disconnect the air pump relay connector b Remove the 2 nuts and air pump relay from the body bracket...

Page 1520: ... that air is discharged from port C If operation is not as specified replace the air switching valve 2 INSPECT AIR PUMP RELAY a Using an ohmmeter check the continuity between each terminals Terminal No Specified Condition 1 2 Continuity 3 4 No Continuity b Check that there is the continuity between the terminal 3 and the 4 when battery voltage applyed between the ter minal 1 and terminal 2 If oper...

Page 1521: ...EC0KG 05 EC 18 EMISSION CONTROL SECONDARY AIR INJECTION SYSTEM 2ZZ GE 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page EC 15 1520 ...

Page 1522: ...e cially careful to protect the electrical system from water b Precautions when handling oxygen sensor 1 Do not allow oxygen sensor to drop or hit against an object 2 Do not allow the sensor to come into contact with water If vehicle is Equipped with Mobile Radio System HAM CB etc If the vehicle is equipped with a mobile communication system refer to the precaution in the IN section 5 AIR INDUCTIO...

Page 1523: ...ting on the SFI parts and wiring connectors g Parts should be replaced as an assembly h Care should be taken when pulling out and inserting wir ing connectors 1 Release the lock and pull out the connector pulling on the connectors 2 Fully insert the connector and check that it is locked i Use SST for inspection or test of the injector or its wiring connector SST 09842 30080 7 FUEL SYSTEM a When di...

Page 1524: ...ndle oil or gasoline be fore installing never use engine gear or brake oil c Install the injector to the delivery pipe and cylinder head as shown in the illustration Before in installing the injec tor must apply spindle oil or gasoline on the place where a delivery pipe or a cylinder head touches on O ring of the injector d Observe these precautions when disconnecting the fuel delivery pipe The st...

Page 1525: ... the fuel tube connector quick type 1 Remove the fuel pipe clamp 2 Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away 3 Be sure to disconnect with hands 4 When the connector and the pipe are stuck pinch the retainer between the hands push and pull the connector to free to disconnect and pull it out Do not use any tool at this ...

Page 1526: ... any fuel leakage g Observe these precautions when handling nylon tube 1 Pay attention not to turn the connected part of the nylon tube and the quick connector with force when connecting them 2 Pay attention not to kink the nylon tube 3 Do not remove the nylon tube 4 Must not close the piping with the nylon tube by bending it h Check that there are no fuel leaks after doing mainte nance anywhere o...

Page 1527: ...d tester connect the positive lead from the battery to terminal 4 of the con necter and the negative lead to terminal 5 f Check that there is pressure in the fuel inlet pipe from the fuel line HINT If there is fuel pressure you will hear the sound if fuel following If there is no pressure check these parts Fusible link Fuses EFI Main relay Fuel pump ECM and Witting connector g Turn the ignition sw...

Page 1528: ...g operations of the fuel tube connector quick type after observing the precau tions S As there is retained pressure in the fuel pipe line pre vent if from splashing inside the engine comport ment f Install SST pressure gauge as shown in the illustration by using SST and fuel tube connector SST 09268 41047 95336 08070 09268 45014 09268 41200 09268 41220 09268 41250 g Wipe off any splattered gasolin...

Page 1529: ...n Stop the engine o Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more If pressure is not as specified check the fuel pump pressure regulator and or injectors p After checking fuel pressure disconnect the negative terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent...

Page 1530: ...itive lead from the battery to terminal 4 of the connector and the negative terminal 5 Check that the pump operates NOTICE S These tests must be done quickly within 10 seconds to prevent the coil burning out S Keep fuel pump as far away from the battery as pos sible S Always do the switching at the battery side If operation is not as specified replace the fuel pump or lead wire 8 RECONNECT FUEL PU...

Page 1531: ...gulator Fuel Pump Filter Rubber Cushion No 2 Fuel Suction Support Tube Joint Clip N m kgf cm ft lbf zO Ring Fuel Pump Spacer Fuel Filter Seal Fuel Pump Harness Emission Tube Fuel Tube Outlet Fuel Pump Sender Gauge Connector Vapor Pressure Sensor Connector Vapor Pressure Sensor Joint Clip 4 0 40 35 in lbf Fuel suction Filter zClip Fuel Sender Gauge SF 10 SFI FUEL PUMP 2005 CELICA RM1131U COMPONENTS...

Page 1532: ...with water b Pull off the tube joint clip from the No 1 fuel suction plate c Disconnect the fuel tube from the fuel pump assembly d Disconnect the emission tube from the fuel pump assem bly e Attach the tape in order to protect the port portion from the dust f Protect the disconnected fuel tube from damage and for eign material by covering it with a plastic bag 5 REMOVE FUEL PUMP ASSEMBLY FROM FUE...

Page 1533: ...t c Using a small screwdriver remove the No 1 fuel suction support NOTICE Do not damage the fuel suction support and fuel suction plate d Disconnect the fuel pump harness from the No 1 fuel suc tion support and fuel pump 3 REMOVE VAPOR PRESSURE SENSOR Pull off the joint clip and remove the vapor pressure sensor from No 1 fuel suction support 4 REMOVE FUEL PUMP Remove the pump from the fuel filter ...

Page 1534: ... 1 FUEL SUCTION SUPPORT a Connect the fuel pump harness to the No 1 fuel suction support and fuel pump b Install the No 1 fuel suction support to the fuel filter c Install the fuel sender gauge to the fuel pump filter so that the distance between the No 1 fuel suction support and the float fulcrum of the fuel sender gauge is 150 mm 5 91 in d Connect the fuel sender gauge connector and earth plate ...

Page 1535: ...ll the 8 bolts and fuel tank vent tube set plate from the fuel tank Torque 4 0 N m 40 kgf cm 35 in lbf 2 CONNECT FUEL TUBE a Clean up around the fuel tube b Connect the fuel tube and emission tube to the fuel pump assembly c Connect the tube joint clip to the fuel suction plate 3 CONNECT FUEL PUMP AND SENDER GAUGE CON NECTOR AND VAPOR PRESSURE SENSOR CON NECTOR HINT Start the engine check for fuel...

Page 1536: ...gulator Floor Service Hole Cover Fuel Pump Sender Gauge Connector 4 0 40 35 in lbf Fuel Tube Outlet Fuel Tank Vent Tube Set Plate Emission Tube No 1 Fuel Suction Support Fuel Filter with Fuel Pump z O Ring z Gasket Tube Joint Clip SFI FUEL PRESSURE REGULATOR SF 15 2005 CELICA RM1131U FUEL PRESSURE REGULATOR COMPONENTS 1535 ...

Page 1537: ...CELICA RM1131U REMOVAL 1 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK See page SF 11 2 REMOVE NO 1 FUEL SUCTION SUPPORT See page SF 12 3 REMOVE FUEL PRESSURE REGULATOR a Pull out the pressure regulator b Remove the O ring from the pressure regulator 1536 ...

Page 1538: ...E REGULATOR a Install the O ring to the pressure regulator HINT Apply a light coat of gasoline to a new O ring and install it to the pressure regulator b Connect the pressure regulator from the fuel filter 2 INSTALL NO 1 FUEL SUCTION SUPPORT See page SF 13 3 INSTALL FUEL PUMP ASSEMBLY TO FUEL TANK See page SF 14 1537 ...

Page 1539: ...injector transmission operation with your finger If no sound or unusual sound is heard check the wiring connec tor injector signal from the ECM d Disconnect the PCV hose from cylinder head cover 3 INSPECT INJECTOR RESISTANCE a Disconnect the injector connector b Using an ohmmeter measure the resistance between the terminals Resistance 13 4 14 2 Ω at 20 C 68 F If the resistance is not as specified ...

Page 1540: ...9 190 13 Fuel Delivery Pipe and Fuel Tube Assembly z O Ring Injector z Grommet Spacer Fuel Pipe Clamp PCV Hose Retainer N m kgf cm ft lbf Specified torque z Non reusable part 7 0 71 62 in lbf Clip SFI INJECTOR SF 19 2005 CELICA RM1131U COMPONENTS 1539 ...

Page 1541: ...ylinder Head Cover 29 290 21 Fuel Delivery Pipe and Fuel Tube Assembly z O Ring Injector z Grommet Spacer N m kgf cm ft lbf Specified torque z Non reusable part 7 0 71 62 in lbf SF 20 SFI INJECTOR 2005 CELICA RM1131U 1540 ...

Page 1542: ...serving the precau tions S As there is retained pressure in the fuel pipe line pre vent it from splashing inside the engine compart ment 4 REMOVE DELIVERY PIPE AND INJECTORS NOTICE Be careful not to drop the injectors when removing the delivery pipe a Disconnect the 4 injector connectors from injector b Remove the 3 bolts and delivery pipe together with the 4 injectors and fuel pipe c Remove the 2...

Page 1543: ...uel pipe SST 09268 41047 CAUTION Perform connecting operations of the fuel tube connector quick type after observing the precautions c Install the grommet and O ring to the injector d Connect SST union and hose to the injector and hold the injector to prevent gasoline from splashing out SST 09268 41047 e Put the injector into a graduated cylinder HINT Install a suitable vinyl tube onto the injecto...

Page 1544: ...jection volume is not as specified replace the injector 2 INSPECT LEAKAGE a In the condition above disconnect the test probes of SST wire from the battery and check the fuel leakage from the injector SST 09842 30080 Fuel drop 1 drop or less per 12 minutes b Turn the ignition switch to LOCK c Disconnect the negative terminal cable from the bat tery d Remove the SST and fuel tube connector SST 09268...

Page 1545: ...livery pipes Install the 4 injectors e Position the injector connector outward f Place the 2 spacers in position on the cylinder head g Apply a light coat of spindle oil or gasoline on the place where a cylinder head touches an O ring of the injector h Place the delivery pipe and fuel pipe together with the 4 injectors in position on the cylinder head i Temporarily install the 2 bolts holding the ...

Page 1546: ... 29 N m 290 kgf cm 21 ft lbf n Tighten the bolt holding the fuel pipe to the cylinder head Torque 9 N m 92 kgf cm 7 ft lbf 2 CONNECT FUEL TUBE a Connect the fuel tube fuel tube connector to the fuel pipe CAUTION Perform connecting operations of the connector quick type after observing the precautions b Install the fuel pipe clamp 3 INSTALL NO 2 CYLINDER HEAD COVER 1545 ...

Page 1547: ...06 SF 26 SFI FUEL TANK AND LINE 2005 CELICA RM1131U FUEL TANK AND LINE PRECAUTION S Always use new gaskets when replacing the fuel tank or component parts S Apply the proper torque to all parts tightened 1546 ...

Page 1548: ...t Plate Fuel Pump Assembly Fuel Tank Fuel Inlet Hose Fuel Inlet Pipe Rear Floor Heat Insulator Fuel Tank No 2 Protector Fuel Tank Band 39 400 29 No 1 Front Floor Heat Insulator z Gasket No 2 Front Floor Heat Insulator Front Exhaust Pipe 62 630 46 z Gasket Tail Pipe Rivet z SFI FUEL TANK AND LINE SF 27 2005 CELICA RM1131U COMPONENTS 1547 ...

Page 1549: ...PECT FUEL TANK AND LINE a Check the fuel lines for cracks or leakage and all connec tions for deformation b Check the fuel tank for deformation cracks fuel leakage or tank band looseness c Check the filter neck for damage or fuel leakage d Hose and tube connections are as shown in the illustra tion If a problem is found repair or replace the part as necessary 1548 ...

Page 1550: ...SF07P 13 B07715 Non reusable part z z O Ring Mass Air Flow Meter Mass Air Flow Meter Connector SFI MASS AIR FLOW MAF METER SF 29 2005 CELICA RM1131U MASS AIR FLOW MAF METER COMPONENTS 1549 ...

Page 1551: ...FI0M7 14 SF 30 SFI MASS AIR FLOW MAF METER 2005 CELICA RM1131U REMOVAL REMOVE AIR FLOW METER Remove the 2 screws air flow meter and O ring 1550 ...

Page 1552: ...2 69 kΩ 20 C 68 F THA E2 0 49 0 67 kΩ 60 C 140 F If the resistance is not as specified replace the MAF meter 2 INSPECT MAF METER OPERATION a Connect the MAF meter connector b Turn the ignition switch to ON c Using a voltmeter connect the positive tester probe to terminal VG and negative tester probe to terminal E2G d Blow air into the MAF meter and check that the voltage fluctuates If operation is...

Page 1553: ...FI0M9 14 SF 32 SFI MASS AIR FLOW MAF METER 2005 CELICA RM1131U INSTALLATION INSTALL AIR FLOW METER Install the air flow meter and a new O ring with 2 screws 1552 ...

Page 1554: ... a Remove the air cleaner assembly with air flow meter b Disconnect the throttle position sensor connector c Using an ohmmeter measure the resistance between each terminal Clearance between lever and stop screw Between terminals Resistance 0 mm 0 in VTA E2 0 2 5 7 kΩ Throttle valve fully open VTA E2 2 0 10 2 kΩ VC E2 2 5 5 9 kΩ d Reconnect the throttle position sensor connector e Reinstall the air...

Page 1555: ... Cap with Air Flow Meter and Air Cleaner Hose Accelerator Cable PCV Hose Throttle Body No 2 Water By pass Pipe z Gasket 21 210 15 Water By pass Hose N m kgf cm ft lbf Specified torque Non reusable part z 7 0 71 62 in lbf Clip SF 34 SFI THROTTLE BODY 1ZZ FE 2005 CELICA RM1131U COMPONENTS 1554 ...

Page 1556: ...sen the air cleaner hose clamp bolt d Disconnect the mass air flow meter connector e Disconnect the 3 air cleaner cap clips f Disconnect the air cleaner hose from the throttle body and remove the air cleaner cap together with the air clean er hose 5 REMOVE THROTTLE BODY a Disconnect the throttle position sensor connector b Disconnect the IAC valve connector c Disconnect the PCV hose from throttle ...

Page 1557: ...B09179 SF 36 SFI THROTTLE BODY 1ZZ FE 2005 CELICA RM1131U f Remove the 2 bolts 2 nuts and throttle body from the in take manifold g Remove the throttle body gasket 1556 ...

Page 1558: ...hat there is no clearance between the throttle stop screw and throttle lever when the closed throttle position 2 INSPECT THROTTLE POSITION SENSOR Using an ohmmeter measure the resistance between each ter minal Clearance between lever and stop screw Between terminals Resistance 0 mm 0 in VTA E2 0 2 5 7 kΩ Throttle valve fully open VTA E2 2 0 10 2 kΩ VC E2 2 5 5 9 kΩ 1557 ...

Page 1559: ...e body with the 2 bolts and 2 nuts Torque 21 N m 210 kgf cm 15 ft lbf c Connect the 2 water by pass hoses to the throttle body d Install the No 2 water by pass pipe with the 2 bolts e Connect the IAC valve connector f Connect the throttle position sensor connector g Connect the PCV hose to throttle body 2 INSTALL AIR CLEANER HOSE AND CAP WITH MAF METER 3 INSTALL NO 2 CYLINDER HEAD COVER 4 FILL RAD...

Page 1560: ...d tester to the DLC3 2 Turn the ignition switch to ON 3 Check that the MIL does not light up 4 When turning the accelerator pedal position sensor lever to the full open position check that the throttle valve opening percentage THROTTLE POS of the CURRENT DATA showns the standard value Standard throttle valve opening percentage 60 or more If operation is not as specified check that the accelerator ...

Page 1561: ...ng test and check that there is no sense of incongruity 2 INSPECT THROTTLE CONTROL MOTOR a Disconnect the throttle control motor connector b Using an ohmmeter measure the motor resistance be tween terminal 1 M and 2 M Motor resistance 0 3 100 Ω at 20 C 68 F If the resistance is not as specified replace the throttle body See page SF 42 c Reconnect the throttle control motor connector 3 INSPECT THRO...

Page 1562: ...hrottle Body Water By pass Hose Air Cleaner Cap with Air Flow Meter and Air Cleaner Hose ECM ECM Outlet Duct N m kgf cm ft lbf Specified torque Non reusable part z 22 220 16 PCV Hose 7 0 71 62 in lbf 22 220 16 Throttle Bracket SFI THROTTLE BODY 2ZZ GE SF 41 2005 CELICA RM1131U COMPONENTS 1561 ...

Page 1563: ...t the 3 air cleaner cap clips f Disconnect the air cleaner hose from the throttle body and remove the air cleaner cap together with the air clean er hose 5 DISCONNECT THROTTLE BODY CONNECTOR Disconnect the throttle body connector 6 DISCONNECT THROTTLE BODY WIRE HARNESS CLAMP Remove the bolt and disconnect the throttle body wire harness clamp from the throttle body 7 REMOVE THROTTLE BRACKET Remove ...

Page 1564: ...B16660 SFI THROTTLE BODY 2ZZ GE SF 43 2005 CELICA RM1131U 10 REMOVE THROTTLE BODY a Remove the 4 nuts and throttle body from the intake man ifold b Remove the 4 bolts and throttle body gasket 1563 ...

Page 1565: ...ater bypass hoses with the clips 3 CONNECT PCV HOSE Connect the PCV hose with the clip 4 INSTALL THROTTLE BRACKET Install the throttle bracket with the 2 bolts 5 CONNECT THROTTLE BODY WIRE HARNESS CLAMP Connect the throttle body wire harness clamp with the bolt to the throttle body Torque 5 0 N m 51 kgf cm 44 in lbf 6 CONNECT THROTTLE BODY CONNECTOR Connect the throttle body connector 7 INSTALL AI...

Page 1566: ...l operating temperature S Idle speed set correctly S Transmission in neutral S A C switch OFF b Using SST connect terminals TC and CG of the DLC3 SST 09843 18020 c After engine speed are kept at 900 1 300 rpm for 5 se conds check that they return to idle speed If the rpm operation is not as specified check the IAC valve wir ing and ECM d Remove the SST from the DLC3 SST 09843 18020 1565 ...

Page 1567: ...aner Hose Throttle Body z Gasket IAC Valve Accelerator Cable Throttle Position Sensor Connector 21 210 15 Water By pass Hose IAC Valve Connector No 2 Water By pass Pipe N m kgf cm ft lbf Specified torque Non reusable part z z Gasket 7 0 71 62 in lbf Clip SF 46 SFI IDLE AIR CONTROL IAC VALVE 2005 CELICA RM1131U COMPONENTS 1566 ...

Page 1568: ...B07721 SF09W 11 SFI IDLE AIR CONTROL IAC VALVE SF 47 2005 CELICA RM1131U REMOVAL 1 REMOVE THROTTLE BODY See page SF 35 2 REMOVE IAC VALVE Remove the 4 screws IAC valve and gasket 1567 ...

Page 1569: ...isconnect the ECT sensor connector from the ECT sen sor d Turn the ignition switch ON e Check that the IAC valve moves HINT Repeat connecting and disconnecting of IAC valve connector several times and check the operation of the valve If operation is not as specified replace the IAC valve f Turn the ignition switch OFF g Connect the ECT sensor connector to the ECT sensor h Disconnect the IAC valve ...

Page 1570: ...SF09Y 07 SFI IDLE AIR CONTROL IAC VALVE SF 49 2005 CELICA RM1131U INSTALLATION Installation is in reverse order of removal See page SF 47 HINT Install the IAC valve with a new gasket 1569 ...

Page 1571: ... VALVE RESISTANCE a Remove the No 2 cylinder head cover b 2ZZ GE Disconnect the 2 PCV hoses c Disconnect the oil control valve connector d Using an ohmmeter measure the resistance between the terminals Resistance 6 9 7 9 Ω at 20 C 68 F If the resistance is not as specified replace the valve e Reconnect the oil control valve connector f Reinstall the V bank cover 1570 ...

Page 1572: ...linder Head Cover z Non reusable part z O Ring Oil Control Valve 1ZZ FE 7 0 71 62 in lbf Clip N m kgf cm ft lbf Specified torque 7 5 80 66 in lbf SFI CAMSHAFTTIMING OIL CONTROL VALVE SF 51 2005 CELICA RM1131U COMPONENTS 1571 ...

Page 1573: ...erator PCV Hose Upper Radiator Support Seal No 2 Cylinder Head Cover Upper Front Fender Apron Seal 58 590 43 29 295 21 Non reusable part z N m kgf cm ft lbf Specified torque z O Ring z O Ring 7 0 71 62 in lbf 25 250 18 8 5 87 75 in lbf 24 240 17 8 5 87 75 in lbf SF 52 SFI CAMSHAFTTIMING OIL CONTROL VALVE 2005 CELICA RM1131U 1572 ...

Page 1574: ...isconnect No 1 ventilation pipe 5 1ZZ FE REMOVE CAMSHAFT TIMING OIL CONTROL VALVE a Disconnect the oil control valve connector b Remove the bolt and oil control valve Torque 7 5 N m 80 kgf cm 66 in lbf c Remove the O ring from the oil control valve HINT At the time of installation please refer to the following items Use a new O ring 6 2ZZ GE REMOVE 2 CAMSHAFT TIMING OIL CONTROL VALVES a Disconnect...

Page 1575: ...ve moves in direction SF 54 SFI CAMSHAFTTIMING OIL CONTROL VALVE 2005 CELICA RM1131U INSPECTION INSPECT CAMSHAFT OIL CONTROL VALVE OPERATION Connect the positive lead from the battery to terminal 1 and negative lead to terminal 2 and check the movement of the valve If operation is not as specified replace the valve 1574 ...

Page 1576: ...SF0SP 13 SFI CAMSHAFTTIMING OIL CONTROL VALVE SF 55 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SF 53 1575 ...

Page 1577: ...INUITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay 3 INSPECT EFI MAIN RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Using an ohmmeter check that there is continuity be tween terminals 3 and 5 If the...

Page 1578: ... CONTINUITY a Using an ohmmeter check that there is continuity be tween terminals 1 and 2 If there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay 3 INSPECT CIRCUIT OPENING RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Using an ohmmeter check that there is continuity be tween terminals 3 ...

Page 1579: ... Flow Meter Connector Air Cleaner Cap Upper Radiator Support Seal Air Cleaner Case VSV for Intake Air Control Air Cleaner SF 58 SFI VSV FOR INTAKE AIR CONTROL VALVE 2005 CELICA RM1131U VSV FOR INTAKE AIR CONTROL VALVE COMPONENTS 1578 ...

Page 1580: ...ity be tween the terminals Resistance 37 44 Ω at 20 C 68 F If there is no continuity replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no continuity be tween each terminal and the body If there is continuity replace the VSV c Inspect the VSV operation 1 Check that air flows from ports E to G 2 Apply battery positive voltage across the terminals 3 Check that air flo...

Page 1581: ...SF15W 07 B09181 VSV for EVAP SF 60 SFI VSV FOR EVAPORATIVE EMISSION EVAP 2005 CELICA RM1131U VSV FOR EVAPORATIVE EMISSION EVAP COMPONENTS 1580 ...

Page 1582: ...e terminals Resistance 27 33 Ω at 20 C 68 F If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air flows with difficulty from port E to port F b Apply battery voltage across the terminals c Check that air flows from port ...

Page 1583: ...SF15Y 08 B09182 Air Cleaner Hose VSV for Canister Closed Valve SF 62 SFI VSV FOR CANISTER CLOSED VALVE CCV 2005 CELICA RM1131U VSV FOR CANISTER CLOSED VALVE CCV COMPONENTS 1582 ...

Page 1584: ... the terminals Resistance At 20 C 68 F 24 30 Ω If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is no continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air flows from ports A to B b Apply battery positive voltage across the terminals c Check that air does not flow from po...

Page 1585: ...ue z Non reusable part Charcoal Canister Assembly Rear Floor Heat Insulator Tail Pipe VSV for Pressure Switching Valve z Gasket 62 630 46 SF 64 SFI VSV FOR PRESSURE SWITCHING VALVE 2005 CELICA RM1131U VSV FOR PRESSURE SWITCHING VALVE COMPONENTS 1584 ...

Page 1586: ...ls Resistance At 20 C 68 F 37 44 Ω At 120 C 248 F 51 62 Ω If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is no continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air does not flow from ports E to F b Apply battery positive voltage across the terminals c Check that air fl...

Page 1587: ...inder Head Cover Engine Coolant Temperature Sensor 7 0 71 62 in lbf Clip 7 0 71 62 in lbf N m kgf cm ft lbf Specified torque z Non reusable part SF 66 SFI ENGINE COOLANT TEMPERATURE ECT SENSOR 2005 CELICA RM1131U ENGINE COOLANT TEMPERATURE ECT SENSOR COMPONENTS 1586 ...

Page 1588: ...PECTION 1 DRAIN ENGINE COOLANT 2 REMOVE NO 2 CYLINDER HEAD COVER 3 REMOVE ECT SENSOR 4 INSPECT ECT SENSOR RESISTANCE Using an ohmmeter measure the resistance between terminals 1 E2 and 2 THW Resistance Refer to the graph If the resistance is not as specified replace the ECT sensor 5 REINSTALL ECT SENSOR Install a new gasket to the ECT sensor 6 REINSTALL NO 2 CYLINDER HEAD COVER 7 FILL RADIATOR WIT...

Page 1589: ...SF164 09 B09184 Rear Seat Cushion Floor Service Hole Cover Vapor Pressure Sensor Joint Clip SF 68 SFI VAPOR PRESSURE SENSOR 2005 CELICA RM1131U VAPOR PRESSURE SENSOR COMPONENTS 1588 ...

Page 1590: ...ion switch ON c Using a voltmeter measure the voltage between connec tor terminals 1 and 3 of the wiring harness side Voltage 4 5 5 5 V d Turn the ignition switch to LOCK e Reconnect the vapor pressure sensor connector 2 INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a Turn the ignition switch ON b Remove the fuel tank cap c Connect a voltmeter to terminals 2 and 3 and measure the output voltage Vo...

Page 1591: ... Seal No 2 Cylinder Head Cover VSV for EVAP Air Cleaner Air Flow Meter Connector PCV Hose Knock Sensor Radiator Reservoir Gasket 21 210 15 Air Cleaner Case Gasket 19 195 14 Intake Manifold No 2 Water By pass Pipe Throttle Body 44 450 33 7 0 71 62 in lbf Clip SF 70 SFI KNOCK SENSOR 2005 CELICA RM1131U KNOCK SENSOR COMPONENTS 1590 ...

Page 1592: ...er Connector Radiator Reservoir Cushion 29 295 21 Air Cleaner Cap Air Cleaner Case Center Bracket Intake Manifold Accelerator Cable Bracket Water By pass Hose Throttle Body z Gasket 34 340 25 46 480 35 Gasket Cushion 22 220 16 Harness Clmap Bolt Knock Sensor 20 204 15 Harness Clamp Bolt 24 245 18 7 0 71 62 in lbf 7 5 76 66 in lbf 22 220 16 SFI KNOCK SENSOR SF 71 2005 CELICA RM1131U 1591 ...

Page 1593: ...ensor SST 09816 30010 5 2ZZ GE REMOVE KNOCK SENSOR a Disconnect the knock sensor connector b Remove the nut and knock sensor 6 1ZZ FE INSPECT KNOCK SENSOR Using an ohmmeter check that there is continuity between the terminal and body If there is continuity replace the sensor 7 2ZZ GE INSPECT KNOCK SENSOR Using an ohmmeter measure the resistance between termi nals Resistance 120 280 kΩ at 20 C 68 F...

Page 1594: ...sor connector 9 2ZZ GE REINSTALL KNOCK SENSOR a Install the knock sensor with the nut b Connect the knock sensor connector 10 REINSTALL INTAKE MANIFOLD See page EM 67 11 REINSTALL RADIATOR RESERVOIR See page CO 23 12 REINSTALL THROTTLE BODY See page SF 35 or SF 42 1593 ...

Page 1595: ...SF167 09 B09185 Heated Oxygen Sensor Bank1 Sensor1 Heated Oxygen Sensor Bank1 Sensor2 SF 74 SFI HEATED OXYGEN SENSOR 2005 CELICA RM1131U HEATED OXYGEN SENSOR COMPONENTS 1594 ...

Page 1596: ... not as specified replace the sensor Torque 44 N m 450 kgf cm 31 ft lbf c Reconnect the oxygen sensor connector 2 INSPECT HEATER RESISTANCE OF HEATED OXY GEN SENSOR Bank1 Sensor2 a Remove the passenger s seat b Take out the floor carpet c Disconnect the oxygen sensor connector d Using an ohmmeter measure the resistance between the terminals B and HT Resistance 11 16 Ω at 20 C 68 F If the resistanc...

Page 1597: ... N m kgf cm ft lbf Specified torque Accelerator Pedal Position Sensor Accelerator Pedal Position Sensor Connector 5 0 51 44 in lbf SF 76 SFI ACCELERATOR PEDAL POSITION SENSOR 2005 CELICA RM1131U ACCELERATOR PEDAL POSITION SENSOR COMPONENTS 1596 ...

Page 1598: ... RM1131U INSPECTION INSPECT ACCELERATOR PEDAL POSITION SENSOR See page DI 391 If necessary replace the accelerator pedal assembly NOTICE S Be care not to give a shock to the accelerator pedal assembly S Be care not to disassemble the accelerator pedal assembly 1597 ...

Page 1599: ...SF0OF 13 B07709 ECM Cover ECM SF 78 SFI ENGINE CONTROL MODULE ECM 2005 CELICA RM1131U ENGINE CONTROL MODULE ECM COMPONENTS 1598 ...

Page 1600: ...SF0OG 10 SFI ENGINE CONTROL MODULE ECM SF 79 2005 CELICA RM1131U INSPECTION 1 REMOVE ECM 2 INSPECT ECM See page DI 40 or DI 333 3 REINSTALL ECM 1599 ...

Page 1601: ...er or OBD II scan tool to the DLC3 b Please refer to the TOYOTA hand held tester or OBD II scan tool operator s manual for further details 3 INSPECT FUEL CUT OFF RPM a Increase the engine speed to at least 3 500 rpm b Use a sound scope to check for injector operating noise c Check that when the throttle lever is released injector op eration noise stops momentary and then resumes HINT Measure with ...

Page 1602: ...non nitrite and non borate coolant with long life hybrid organic acid technology up to the FULL line 2 CHECK ENGINE COOLANT QUALITY a Remove the reservoir cap CAUTION To avoid the danger of being burned do not remove the reservoir the cap while the engine and radia tor are still hot as fluid and steam can be blown out under pressure b There should not be any excessive deposits of rust or scale aro...

Page 1603: ...nion on the left rear of the cylinder block and drain the coolant c Close the drain plugs Torque 12 7 N m 130 kgf cm 9 ft lbf for engine 2 FILL ENGINE COOLANT a Remove the upper front fender apron seal and upper ra diator support seal b Remove the 2 bolts c Disconnect the 3 clamps and 2 hoses then place hoses on air cleaner case d Lift the engine coolant reservoir and hook it on a hood latch to fi...

Page 1604: ...3 7 liters coolant squeeze the radiator lower hose several times while blocking the hole in the bleeder plug with a finger and surely supply the coolant g Start the engine with the reservoir cap and the bleeder plug removed and warm it up until the cooling fan blows first and then stops HINT At this time the A C switch should be OFF h Additionally supply 500 cc coolant with the engine idling i Ins...

Page 1605: ...p 2ZZ GE Water Pump Pulley Drive Belt 1ZZ FE Water Pump RH Engine Under Cover z O Ring 15 153 11 9 0 92 80 in lbf 9 0 92 80 in lbf See page CO 7 11 113 8 N m kgf cm ft lbf Specified torque zNon reusable part Belt A Belt B CO 4 COOLING WATER PUMP 2005 CELICA RM1131U WATER PUMP COMPONENTS 1604 ...

Page 1606: ...nd O ring b Clean up the engine coolant from the water chamber room 5 2ZZ GE REMOVE WATER PUMP a Using SST remove the 4 water pump pulley set bolts SST 09960 10010 09962 01000 09963 00600 b Remove the water pump pulley c Remove the 6 bolts water pump and O ring d Clean up the engine coolant from the water chamber room NOTICE Do not remove the RH engine mounting bracket and gener ator when the wate...

Page 1607: ... RM1131U INSPECTION INSPECT WATER PUMP a Visually check the drain hole for coolant leakage If leakage is found replace the water pump b Turn the pulley and check that the water pump bearing moves smoothly and quietly If necessary replace the water pump 1606 ...

Page 1608: ...38 in 2 2ZZ GE INSTALL WATER PUMP a Place a new O ring on the timing chain cover b Install the water pump with the 6 bolts Torque 9 0 N m 92 kgf cm 80 in lbf HINT Each bolt length is indicated in the illustration A 30 mm 1 18 in B 35 mm 1 38 in c Install the water pump pulley d Using SST tighten the 4 water pump pulley set bolts SST 09960 10010 09962 01000 09963 00600 Torque 15 N m 153 kgf cm 11 f...

Page 1609: ...o 2 Cylinder Head Cover Drive Belt Generator 2ZZ GE No 2 Cylinder Cover Generator Wire Generator Connector Wire Clamp z Gasket Water Inlet Thermostat 10 100 7 N m kgf cm ft lbf Specified torque Non reusable part z CO 8 COOLING THERMOSTAT 2005 CELICA RM1131U THERMOSTAT COMPONENTS 1608 ...

Page 1610: ...g of cooling efficiency Do not remove the thermostat even if the engine tends to overheat 1 DRAIN ENGINE COOLANT 2 REMOVE DRIVE BELT AND GENERATOR See page CH 7 3 REMOVE WATER INLET AND THERMOSTAT a Remove the 2 nuts and disconnect the water inlet from the cylinder block b Remove the thermostat c Remove the gasket from the thermostat 1609 ...

Page 1611: ...e water b Check the valve opening temperature Valve opening temperature 80 0 84 0 C 176 183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve lift 10 mm 0 39 in or more at 90 C 194 F If the valve lift is not as specified replace the thermostat d Check that the valve is fully closed when the thermostat is at low temperatures below 40 C 104 F ...

Page 1612: ...at b Install the thermostat with the jiggle valve upward HINT The jiggle valve may be set within 10 of either side of the pre scribed position 2 INSTALL WATER INLET Install the water inlet with the 2 nuts Torque 10 N m 100 kgf cm 7 ft lbf 3 INSTALL GENERATOR AND DRIVE BELT See page CH 17 4 FILL WITH ENGINE COOLANT 5 START ENGINE AND CHECK FOR COOLANT LEAKS 1611 ...

Page 1613: ...e between the steam cleaner and the core is too close there is a possibility of damaging the fin so keep the following injection distance Injection Pressure Injection Distance 2 942 4 903 kpa 30 50 kg cm2 427 711 psi 300 mm 11 811 in 4 903 7 845 kpa 50 80 kg cm2 711 1 138 psi 500 mm 19 685 in S If the fins are bent straighten them with a screwdriver or pliers S Never apply water directly onto the ...

Page 1614: ... tester at an angle of over 30 above the hor izontal a Using a radiator cap tester slowly pump the tester and check that air is coming from the vacuum valve Pump speed 1 push 3 seconds or more NOTICE Push the pump at a constant speed If air is not coming from the vacuum valve replace the reservoir cap b Pump the tester and measure the relief valve opening pressure Pump speed 1 push within 1 second...

Page 1615: ...th coolant and attach a radiator cap tes ter b Warm up the engine c Pump it to 118 kPa 1 2 kgf cm2 17 1 psi and check that the pressure does not drop If the pressure drops check the hoses radiator or water pump for leaks If no external leaks are found check the heater core cylinder block and head 4 REINSTALL RESERVOIR CAP 1614 ...

Page 1616: ...Lock VSV for EVAP Center Brace MAF Sensor Connector Air Cleaner Cap Air Filter Air Cleaner Case Bumper Cover Lower Radiator Support Bushing Upper Radiator Support Bushing 2ZZ GE Air Pump Assembly N m kgf cm ft lbf Specified torque 5 0 51 44 in lbf 5 5 56 49 in lbf 10 102 7 6 9 70 60 in lbf 9 8 100 87 in lbf 8 0 82 71 in lbf 5 0 51 44 in lbf COOLING RADIATOR CO 15 2005 CELICA RM1131U COMPONENTS 161...

Page 1617: ... in lbf N m kgf cm ft lbf Specified torque B08772 DENSO Made zNon reusable part z O Ring Oil Cooler Tank Plate Washer z O Ring Plate Washer z O Ring Core Drain Plug z O Ring z O Ring Tank Cooler Pipe CO 16 COOLING RADIATOR 2005 CELICA RM1131U 1616 ...

Page 1618: ... connector b Disconnect the No 2 electric cooling fan connector c Disconnect the upper radiator hose d Disconnect the lower radiator hose e Disconnect the 2 A T oil cooler hoses f Remove the 3 bolts and disconnect the hood lock g Remove the 2 bolts and center brace h Remove the 4 bolts and 2 upper condenser supports i w Cruise control system Remove the bolt and disconnect the cruise control actua ...

Page 1619: ...the stopper bolts so that dimension B shown in the diagram is 0 2 0 3 mm 0 008 0 012 in NOTICE If this adjustment is not done the claw may be damaged 3 DENSO Made UNCAULK LOCK PLATES Using SST to release the caulking squeeze the handle until stopped by the stopper bolts SST 09230 01010 4 DENSO Made REMOVE TANKS AND O RINGS Lightly tap the bracket of the radiator or radiator inlet or outlet with a ...

Page 1620: ... the sides of the lock plate groove are deformed reas sembly of the tank will be impossible S Therefore first correct any deformation with pliers or simi lar object Water leakage will result if the bottom of the lock plate groove is damaged NOTICE The radiator can only be recaulked 2 times After the 2nd time the radiator core must be replaced 1619 ...

Page 1621: ...ion indicated as shown in the illustration Torque 14 7 N m 150 kgf cm 11 ft lbf 2 DENSO Made INSTALL NEW O RINGS AND TANKS a After checking that there are no foreign objects in the lock plate groove install the new O ring without twisting it HINT When cleaning the lock plate groove lightly rub it with sand pa per without scratching it b Install the tank without damaging the O ring c Tap the lock p...

Page 1622: ...010 HINT S Do not stake the areas protruding around the pipes brackets or tank rids S The points shown in the illustration and oil cooler near here A T cannot be staked with SST Use wrap vinyl tape around the tip of a pair or similar object and be careful not to damage the core plates b Check the lock plate height H after completing the caulking Plate height 7 40 7 80 mm 0 2913 0 3071 in If not wi...

Page 1623: ...or cap tester apply pressure to the radiator Test pressure 177 kPa 1 8 kgf cm2 26 psi e Submerge the radiator in water f Inspect for leaks HINT On radiators with resin tanks there is a clearance between the tank and lock plate where a minute amount of air will remain giving the appearance of an air leak when the radiator is sub merged in water Therefore before doing the water leak test first swish...

Page 1624: ...s with the 4 bolts g Install the center brace with the 2 bolts h Install the hood lock with the 3 bolts i Connect the 2 A T oil cooler hoses j Connect the lower radiator hose k Connect the upper radiator hose l Connect the No 1 electric cooling fan connector m Connect the No 2 electric cooling fan connector 3 INSTALL ENGINE COOLANT RESERVOIR a Install the engine coolant reservoir with the bolt Tor...

Page 1625: ... Check that the cooling fan rotates If not check the engine main relay cooling fan relay cooling fan fuses and check for short circuit between the cooling fan relay and ECT sensor e Reconnect the ECT sensor connector 2 CHECK COOLING FAN OPERATION WITH HIGH TEM PERATURE Above 93 C 199 F a Start the engine and raise coolant temperature to above 93 C 199 F b Check that the cooling fan rotates If not ...

Page 1626: ...Electric Cooling Fan MAF Sensor Connector Air Cleaner Cap Air Filter Air Cleaner Case Bumper Cover VSV for EVAP 2ZZ GE Air Pump Assembly 1ZZ FE Cruise Control Actuator Upper Radiator Support Bushing 8 0 82 71 in lbf 5 5 56 49 in lbf 5 0 51 44 in lbf 68 693 50 6 9 70 60 in lbf 9 8 100 87 in lbf 10 102 7 5 0 51 41 in lbf 5 0 51 44 in lbf N m kgf cm ft lbf Specified torque COOLING ELECTRIC COOLING FA...

Page 1627: ...B08788 w A C Fan Shroud No 2 Fan Motor No 1 Fan Motor Fan w o A C Fan No 1 Fan Motor Fan Shroud CO 26 COOLING ELECTRIC COOLING FAN 2005 CELICA RM1131U 1626 ...

Page 1628: ...TOR UPPER SUPPORT a Remove the air cleaner assembly b Remove the engine coolant reservoir c Remove the 3 bolts and disconnect the hood lock d Remove the 2 bolts and center brace e Remove the 4 bolts and 2 upper condenser supports f w Cruise control system Remove the bolt and disconnect the cruise control actuator g Remove the 2 bolts and radiator upper support 6 REMOVE COOLING FAN a Disconnect the...

Page 1629: ...COOLING ELECTRIC COOLING FAN 2005 CELICA RM1131U DISASSEMBLY 1 REMOVE FAN S Remove the nut and fan 2 REMOVE FAN MOTOR S a Disconnect the wire and connector holder from the fan shroud b Remove the 3 screws and fan motor 1628 ...

Page 1630: ...LICA RM1131U REASSEMBLY 1 INSTALL FAN MOTOR S a Install the fan motor with the 3 screws Torque 2 55 N m 26 kgf cm 23 in lbf b Install the wire and connector holder to the fan shroud 2 INSTALL FAN S Install the fan with the nut Torque 6 18 N m 63 kgf cm 55 in lbf 1629 ...

Page 1631: ...upport with the 2 bolts b w Cruise control system Install the cruise control actuator with the 3 bolts c Install the 2 upper condenser supports with the 4 bolts d Install the center brace with the 2 bolts e Install the hood lock with the 3 bolts f Install the engine coolant reservoir g Install the air cleaner assembly 3 INSTALL FRONT BUMPER See page BO 4 4 2ZZ GE INSTALL AIR PUMP ASSEMBLY See page...

Page 1632: ...tween terminals 3 and 5 If there is continuity replace the relay d Inspect the No 1 cooling fan relay operation 1 Apply battery positive voltage across terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 If there is no continuity replace the relay e Reinstall the No 3 cooling fan relay f Reinstall the relay box cover 2 w A C INSPECT NO 2 COOLING FAN RELAY...

Page 1633: ...he relay e Reinstall the No 2 cooling fan relay f Reinstall the relay box cover 3 w A C INSPECT NO 3 COOLING FAN RELAY a Remove the relay box cover b Remove the No 3 cooling fan relay Marking FAN No 3 c Inspect the No 3 cooling fan relay continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no conti...

Page 1634: ...g up the engine and then 5 minutes after the en gine stop oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to the F mark NOTICE Do not fill with engine oil above the F mark 3 REMOVE OIL PRESSURE SWITCH AND INSTALL OIL PRESSURE GAUGE a Using SST remove the oil pressure switch SST 09816 30010 b Install the oil pressure gauge 4 WARM UP ENGINE Allow...

Page 1635: ...U b Apply adhesive to 2 or 3 threads of the oil pressure switch Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Using SST install the oil pressure switch SST 09816 30010 Torque 13 N m 130 kgf cm 9 ft lbf 7 START ENGINE AND CHECK FOR LEAKS 1634 ...

Page 1636: ...soline thinners or solvents S In order to preserve the environment used oil and used oil filter must be disposed of only at designated disposal sites 1 REMOVE CENTER ENGIEN UNDER COVER 2 DRAIN ENGINE OIL a Remove the oil filter cap b Remove the oil drain plug and drain the oil into a contain er 3 REPLACE OIL FILTER a Using SST remove the oil filter SST 09228 06501 b Check and clean the oil filter ...

Page 1637: ...er change 3 5 liters 3 7 US qts 3 1 lmp qts Dry fill 4 2 liters 4 4 US qts 3 7 lmp qts 2ZZ GE w Oil filter change 4 4 liters 4 8 US qts 4 0 Imp qts w o Oil filter change 4 2 liters 4 6 US qts 3 8 Imp qts Dry fill 4 8 liters 5 1 US qts 4 2 Imp ats c Install the oil filter cap 5 START ENGINE AND CHECK FOR OIL LEAKS 6 INSTALL CENTER ENGINE UNDER COVER 7 RECHECK ENGINE OIL LEVEL 1636 ...

Page 1638: ...FE RH Engine Mounting Insulator 52 530 38 52 530 38 2ZZ GE RH Engine Mounting Insulator 52 530 38 RH Engine Under Cover N m kgf cm ft lbf Specified torque 52 530 38 52 530 38 52 530 38 52 530 38 2ZZ GE Air Switching Valve 2ZZ GE Front Exhaust Pipe z Gasket z Gasket 43 440 32 O Ring O Ring Non reusable part z 43 440 32 43 440 32 zGasket LUBRICATION OIL PUMP LU 5 2005 CELICA RM1131U OIL PUMP COMPONE...

Page 1639: ...z Crankshaft Position Sensor No 2 Cylinder Head Cover Ignition Coil w Igniter Cylinder Head Cover PCV Hose Gasket Timing Chain Chain Tensioner Slipper Crank Angle Sensor Plate Crankshaft Timing Sprocket Chain Vibration Damper Oil Pump z Gasket x 5 N m kgf cm ft lbf Specified torque zNon reusable part 9 0 92 80 in lbf LU 6 LUBRICATION OIL PUMP 2005 CELICA RM1131U 1638 ...

Page 1640: ...er Timing Chain Chain Vibration Damper Oil Pump Ignition Coil w Igniter x 4 No 2 Cylinder Head Cover PCV Hose Gasket Gasket z No 3 Ventilation Pipe Crank Angle Sensor Plate N m kgf cm ft lbf Specified torque zNon reusable part Crankshaft Timing Sprocket x 5 Gasket z Oil Dipstick O Ring z Oil Guide 9 0 92 80 in lbf O Ring z Gasket z Exhaust Manifold Upper Heated Insulator Lower Heated Insulator Exh...

Page 1641: ...B08736 Plug Spring Relief Valve Oil Pump Body Driven Rotor Drive Rotor Oil Pump Body Cover x3 1 x5 2 1 1ZZ FE 2 2ZZ GE LU 8 LUBRICATION OIL PUMP 2005 CELICA RM1131U 1640 ...

Page 1642: ...B08737 LUBRICATION OIL PUMP LU 9 2005 CELICA RM1131U REMOVAL 1 DRAIN ENGINE OIL 2 REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET See pages EM 19 3 REMOVE OIL PUMP Remove the 5 bolts oil pump and gasket 1641 ...

Page 1643: ...31U DISASSEMBLY 1 REMOVE RELIEF VALVE Remove the plug spring and relief valve 2 REMOVE DRIVE AND DRIVEN ROTORS a 1ZZ FE Remove the 3 screws pump body cover drive and driven rotors b 2ZZ GE Remove the 5 screws pump body cover drive and driven rotors 1642 ...

Page 1644: ...n the rotors and precision straight edge Standard side clearance 1ZZ FE 0 025 0 071 mm 0 00098 0 00280 in 2ZZ GE 0 030 0 080 mm 0 00118 0 00314 in Maximum side clearance 1ZZ FE 0 071 mm 0 00280 in 2ZZ GE 0 160 mm 0 00630 in If the side clearance is greater than maximum replace the ro tors as a set If necessary replace the oil pump assembly 4 INSPECT ROTOR BODY CLEARANCE Using a feeler gauge measur...

Page 1645: ...e the clearance between the drive and driven rotor tips Standard tip clearance 1ZZ FE 0 040 0 160 mm 0 00157 0 00630 in 2ZZ GE 0 060 0 180 mm 0 00236 0 00709 in Maximum tip clearance 1ZZ FE 0 16 mm 0 00630 in 2ZZ GE 0 35 mm 0 01378 in If the tip clearance is greater than maximum replace the rotors as a set 1644 ...

Page 1646: ... the pump body cover side b 1ZZ FE Install the pump body cover with the 3 screws Torque 10 5 N m 107 kgf cm 8 ft lbf c 2ZZ GE Install the pump body cover with the 5 screws Torque 10 5 N m 107 kgf cm 8 ft lbf 2 INSTALL RELIEF VALVE Insert the relief valve and spring into the pump body hole and install the plug Torque 1ZZ FE 37 N m 375 kgf cm 27 ft lbf 2ZZ GE 49 N m 500 kgf cm 36 ft lbf 1645 ...

Page 1647: ...age the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft and slide the oil pump c Install the oil pump with the 5 bolts Torque 9 0 N m 92 kgf cm 80 in lbf 2 INSTALL CRANKSHAFT TIMING SPROCKET AND TIMING CHAIN See pages EM 26 3 FILL ENGINE WITH OIL 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE OIL LEVEL 1646 ...

Page 1648: ...ing Upper Main Bearing Crankshaft Thrust Washer Crankshaft Oil Pan Baffle 9 0 92 80 in lbf Bearing Cap Assembly z Gasket 43 438 32 Oil Filter Union Oil Filter 9 0 92 80 in lbf 37 378 27 Oil Strainer z Gasket Oil Pan 9 0 92 80 in lbf 1st 22 225 16 2nd 44 449 32 3rd Turn 45 See page EM 108 4rd Turn 45 18 185 13 9 0 92 80 in lbf See page EM 108 1st 30 306 22 2nd Turn 90 N m kgf cm ft lbf Specified to...

Page 1649: ...6 P11778 LU 16 LUBRICATION OIL NOZZLE 2ZZ GE 2005 CELICA RM1131U REMOVAL 1 REMOVE CRANKSHAFT See page EM 91 2 REMOVE OIL NOZZLE WITH RELIEF VALVE Using a 5 mm hexagon wrench remove the bolt and oil nozzle 1648 ...

Page 1650: ... 06 B03055 LUBRICATION OIL NOZZLE 2ZZ GE LU 17 2005 CELICA RM1131U INSPECTION INSPECT RELIEF VALVE OIL NOZZLE Push the valve with a wooden stick to check if it is stuck If stuck replace the relief valve 1649 ...

Page 1651: ...N OIL NOZZLE 2ZZ GE 2005 CELICA RM1131U INSTALLATION 1 INSTALL OIL NOZZLE WITH RELIEF VALVE Using a 5 mm hexagon wrench install the oil nozzle with the bolt Torque 9 0 N m 92 kgf cm 80 in lbf 2 INSTALL CRANKSHAFT See page EM 108 1650 ...

Page 1652: ...K TEST Check that the spark occurs 1 Remove the ignition coils with igniter See page IG 6 2 Using a 16 mm 0 63 in plug wrench remove the spark plugs 3 Install the spark plugs to each ignition coils with ig niter and connect the ignition coil connectors 4 Disconnect the 4 injector connectors 5 Ground the spark plugs 6 Check if spark occurs while engine is being cranked NOTICE To prevent gasoline fr...

Page 1653: ...ct securely Check wiring between ignition switch to ignition coil with igniter Check ECM See page IN 30 NO OK OK OK OK BAD BAD BAD BAD BAD SENSOR See step 4 IGNITER CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER AND PERFORM SPARK TEST AGAIN OK Replace the ignition coil with igniter NO OK 985 1 600 Ω 1 265 1 890 Ω B08752 16 mm 0 63 in Plug Wrench IG 2 IGNITION IGNITION SYSTEM 2005 CELICA RM1131U If...

Page 1654: ... before using the spark plug cleaner d Check the spark plug for thread damage and insulator damage If abnormal replace the spark plug Recommended spark plug 1ZZ FE DENSO made SK16R11 NGK made IFR5A11 2ZZ GE DENSO made SK20R11 NGK made IFR6A11 e Adjust electrode gap Carefully bend the outer electrode to obtain the correct electrode gap Electrode gap 1 1 mm 0 043 in f Using a 16 mm 0 63 in plug wren...

Page 1655: ...N SENSOR a Disconnect the camshaft position sensor connector b Using an ohmmeter measure the resistance between ter minals Resistance Cold 835 1 400 Ω Hot 1 060 1 645 Ω If the resistance is not as specified replace the camshaft posi tion sensor c Connect the camshaft position sensor connector 1654 ...

Page 1656: ... N m kgf cm ft lbf Wire Harness Protector Ignition Coil with Ignitor No 2 Cylinder Head Cover 2ZZ GE 1ZZ FE No 2 Cylinder Head Cover 9 0 92 79 in lbf x4 x4 IGNITION IGNITION COIL IG 5 2005 CELICA RM1131U IGNITION COIL COMPONENTS 1655 ...

Page 1657: ...YLINDER HEAD COVER 2 REMOVE IGNITION COILS WITH IGNITER FROM SPARK PLUGS a Remove the 2 bolts and disconnect the wire harness pro tector b Disconnect the 4 ignition coil connectors c Remove the 4 bolts and pull out the 4 ignition coils with igniter Torque 9 0 N m 92 kgf cm 79 in lbf 1656 ...

Page 1658: ...IG0BQ 06 IGNITION IGNITION COIL IG 7 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page IG 6 1657 ...

Page 1659: ... Cylinder Head Cover 2ZZ GE No 2 Cylinder Head Cover 1ZZ FE Camshaft Position Sensor 8 8 90 78 in lbf 2ZZ GE 1ZZ FE Camshaft Position Sensor 8 8 90 78 in lbf IG 8 IGNITION CAMSHAFT POSITION SENSOR 2005 CELICA RM1131U CAMSHAFT POSITION SENSOR COMPONENTS 1658 ...

Page 1660: ...AD COVER 2 1ZZ FE REMOVE CAMSHAFT POSITION SENSOR a Disconnect the connector b Remove the bolt and camshaft position sensor Torque 8 8 N m 90 kgf cm 78 in lbf 3 2ZZ GE REMOVE CAMSHAFT POSITION SENSOR a Disconnect the connector b Remove the 2 bolts and camshaft position sensor Torque 8 8 N m 90 kgf cm 78 in lbf 1659 ...

Page 1661: ...IG0EQ 05 IG 10 IGNITION CAMSHAFT POSITION SENSOR 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page IG 9 1660 ...

Page 1662: ...Filter Air Cleaner Case Throttle Position Sensor Connector z Gasket Intake Manifold Wire Harness Bracket Engine Wire zGasket IAC Valve Connector Throttle Body Crankshaft Position Sensor 8 8 90 78 in lbf N m kgf cm ft lbf Specified torque zNon reusable part IGNITION CRANKSHAFT POSITION SENSOR IG 11 2005 CELICA RM1131U CRANKSHAFT POSITION SENSOR COMPONENTS 1661 ...

Page 1663: ...racket Intake Manifold zGasket MAF Sensor Connector Air Cleaner Cap Air Filter Air Cleaner Case Throttle Position Sensor Connector zGasket IAC Valve Connector Throttle Body Engine Wire 8 8 90 78 in lbf Crankshaft Position Sensor N m kgf cm ft lbf Specified torque zNon reusable part IG 12 IGNITION CRANKSHAFT POSITION SENSOR 2005 CELICA RM1131U 1662 ...

Page 1664: ...ELICA RM1131U REMOVAL 1 REMOVE INTAKE MANIFOLD See page EM 44 2 REMOVE ENGINE UNDER COVER RH 3 REMOVE CRANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove the 2 bolt and crankshaft position sensor Torque 8 8 N m 90 kgf cm 78 in lbf 1663 ...

Page 1665: ... tempera ture of the sensor itself Cold is from 10 C 14 F to 50 C 122 F and Hot is from 50 C 122 F to 100 C 212 F INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter measure the resistance between termi nals Resistance Cold 1 630 2 740 Ω Hot 2 065 3 225 Ω If the resistance is not as specified replace the crankshaft posi tion sensor 1664 ...

Page 1666: ...IG0BW 07 IGNITION CRANKSHAFT POSITION SENSOR IG 15 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page IG 13 1665 ...

Page 1667: ...RTING SYSTEM ST 1 2005 CELICA RM1131U STARTING SYSTEM ON VEHICLE INSPECTION NOTICE Before changing the starter check the following items again S Connector connection S Accessory installation e g theft deterrent system 1666 ...

Page 1668: ... Under Cover LH Engine Under Cover Air Cleaner Cap Upper Radiator Support Seal Air Cleaner Air Cleaner Case Air Flow Meter Connector 37 380 28 37 380 28 Specified torque N m kgf cm ft lbf VSV for EVAP ST 2 STARTING STARTER 2005 CELICA RM1131U STARTER COMPONENTS 1667 ...

Page 1669: ...ve Washer Terminal Insulator Packing O Ring Magnetic Switch Assembly z Front Bearing z Rear Bearing z Dust Protector Return Spring z Gasket z Non reusable part Specified torque zTerminal 30 Kit Part z Terminal C Kit Part 17 170 12 N m kgf cm ft lbf z Dust Protector Through Bolt O Ring Wave Washer Terminal Insulator Terminal Nut 17 170 12 Starter Housing 2ZZ GE z Front Bearing STARTING STARTER ST 3...

Page 1670: ...REMOVAL 1 REMOVE UPPER RADIATOR SUPPORT SEAL 2 REMOVE AIR CLEANER ASSEMBLY See page EM 76 3 REMOVE RH AND LH ENGINE UNDER COVER 4 REMOVE STARTER a Disconnect the starter connector b Remove the nut and disconnect the starter wire c Remove the 2 bolts and starter 1669 ...

Page 1671: ...he lead wire from the magnetic switch terminal b Remove the 2 through bolts c Remove the 2 screws and end cover from the field frame d Remove the O ring from the field frame e Using a screwdriver hold the spring tank back and dis connect the brush from the brush holder Disconnect the 4 brushes and remove the brush holder f Pull out the field frame from the magnetic switch assem bly g Remove the O ...

Page 1672: ...ve these parts from the magnetic switch assembly 1 Starter housing 2 Idler gear 3 Bearing 4 Clutch assembly 5 Return spring 3 REMOVE STEEL BALL Using a magnetic finger remove the steel ball from the clutch shaft hole 4 REMOVE ARMATURE FROM MAGNETIC SWITCH AS SEMBLY a 1ZZ FE Remove the armature from the magnetic switch assem bly b 2ZZ GE Using a press remove the armature from the magnetic switch as...

Page 1673: ...If the surface is dirty or burnt correct with sandpaper No 400 or a lathe 4 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial gauge measure the circle runout Maximum circle runout 0 05 mm 0 0020 in If the circle runout is greater than maximum correct it on a lathe 5 INSPECT COMMUTATOR DIAMETER Using vernier calipers measure the commutator diameter Standard diameter...

Page 1674: ...eplace the field frame 9 INSPECT BRUSH LENGTH Using vernier calipers measure the brush length Standard length 15 5 mm 0 610 in Minimum length 10 0 mm 0 394 in If the length is less than minimum replace the brush holder and field frame 10 INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring sepa rates from the brush 14 kW type Standard spring installed load 17 6 23 5 N...

Page 1675: ...replace the gear or clutch assembly If damaged also check the drive plate ring gear for wear or damage 13 INSPECT CLUTCH Rotate the clutch pinion gear clockwise and check that it turns freely Try to rotate the clutch pinion gear counter clockwise and check that it locks If necessary replace the clutch assembly 14 DO MAGNETIC SWITCH PULL IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there ...

Page 1676: ...0031 c Using a press press in a new rear bearing 3 REMOVE MAGNETIC SWITCH END COVER a Remove the 3 bolts end cover gasket and plunger b Inspect the contact plate for wear Using vernier calipers measure the contact plate for depth of wear Maximum wear 0 9 mm 0 035 in If the depth of wear is greater than the maximum replace the contact plate c Remove the terminal kit parts 1 Using SST loosen the ter...

Page 1677: ... 3 Install a terminal bolt 4 Install a O ring 5 Install a packing and terminal insulator outside Install the packing to the terminal insulator and install them HINT Match the protrusion of the insulator with the indentation of the housing 6 Install a wave washer 7 Install a terminal nut e Temporarily install new terminal C kit parts 1 Install a terminal insulator inside 2 Install a contact plate 3...

Page 1678: ...re of the press when 981 N 100 kgf 221 Ibf of force is applied Gauge pressure If the contact plate is not pressed down with the specified pres sure the contact plate may tilt due to coil deformation or the tightening of the nut 2 Using SST tighten the nuts to the specified torque SST 09810 38140 Torque 17 N m 173 kgf cm 12 ft lbf NOTICE If the nut is over tightened it may cause cracks on the in si...

Page 1679: ...he projection of the ring is positioned in the narrowest part b Apply grease to the armature bearings c 1ZZ FE Install the armature to the magnetic switch assembly d 2ZZ GE Using a press install the armature to the magnetic switch assembly 2 INSERT STEEL BALL INTO CLUTCH SHAFT HOLE a Apply grease to the steel ball b Insert the steel ball into the clutch shaft hole 3 INSTALL STARTER HOUSING CLUTCH ...

Page 1680: ...field frame 5 INSTALL BRUSH HOLDER a Place the brush holder on the field frame b Using a screwdriver hold the brush spring back and con nect the brush into the brush holder Connect the 4 brushes NOTICE Check that the positive lead wires are not grounded 6 INSTALL END COVER a Install a new O ring to the groove of the field frame b Install the end cover to the field frame with the 2 screws Torque 3 ...

Page 1681: ...Check that the clutch pinion gear moves outward 2 DO HOLD IN TEST With battery connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Check that the clutch pinion gear remains out 3 INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative lead from the switch body Check that the clutch pinion gear returns inward 4 DO NO LOAD PERFORMANCE TEST a Connect the ...

Page 1682: ... 2 bolts and starter HINT Each bolt length is indicated in the illustration Bolt length A 64 mm 2 72 in B 54 mm 2 13 in b Connect the starter wire and install the nut c Connect the starter connector 2 INSTALL RH AND LH ENGINE UNDER COVER 3 INSTALL AIR CLEANER ASSEMBLY 4 INSTALL UPPER RADIATOR SUPPORT SEAL 1681 ...

Page 1683: ...nuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay b Inspect the relay operation 1 Apply battery positive voltage across terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 If th...

Page 1684: ...ION S Check that the battery cables are connected to the correct terminals S Disconnect the battery cables when the battery is given a quick charge S Do not perform tests with a high voltage insulation resistance tester S Never disconnect the battery while the engine is running 1683 ...

Page 1685: ...ecific gravity is less than specification charge the bat tery 3 CHECK BATTERY VOLTAGE a After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the en gine turn the ignition switch ON and turn on the electrical system headlight blower motor rear defogger etc for 60 seconds to remove the surface charge b Turn the ignition switch OFF and turn off the elec...

Page 1686: ...e belt tensioner pulley to make sure the drive belt will not slip off the pulley If necessary replace the belt tensioner HINT S After installing a belt check that it fits properly in the ribbed grooves S Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley S After installing a new belts run the engine for about 5 min utes and check the belt te...

Page 1687: ...or S Connect the positive lead of the voltmeter to ter minal B of the generator S Ground the negative lead of the voltmeter b Check the charging circuit as follows With the engine running from idle to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperage 10 A or less Standard voltage 13 2 14 8 V If the value is not specified check the generator 9 INSPECT CHARGING CIRCUIT WITH ...

Page 1688: ...Front Fender Apron Seal No 2 Cylinder Head Cover No 2 Cylinder Head Cover 29 295 21 Specified torque N m kgf cm ft lbf Generator Bracket 25 245 18 1ZZ FE 54 540 40 2ZZ GE 58 590 43 2ZZ GE 7 0 71 62 in lbf 7 0 71 62 in lbf Clip 1 CHARGING GENERATOR CH 5 2005 CELICA RM1131U GENERATOR COMPONENTS 1687 ...

Page 1689: ... Rear End Cover Brush Holder Cover Terminal Insulator Brush Holder Seal Plate Voltage Regulator Rectifier Holder Rubber Insulator Wire Clip Rectifier End Frame z Front Bearing z Rear Bearing z Non reusable part 111 1 125 81 Specified torque N m kgf cm ft lbf CH 6 CHARGING GENERATOR 2005 CELICA RM1131U 1688 ...

Page 1690: ...lt and then remove the belt b Carefully return the tensioner to the unloaded position 2 REMOVE GENERATOR a Disconnect the wire clamp from the wire clip on the rectifi er end frame b Remove the rubber cap and nut and disconnect the gen erator wire c Disconnect the generator connector d 2ZZ GE Remove the 2 bolts and generator bracket e Remove the 2 bolts and generator 1689 ...

Page 1691: ...lder cover from the brush holder b Remove the 5 screws brush holder and voltage regulator c Remove the seal plate from the rectifier end frame 3 REMOVE RECTIFIER HOLDER a Remove the 4 screws and rectifier holder b Remove the 4 rubber insulators 4 REMOVE PULLEY a Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 09820 63011 Torque 39 N m 400 kgf cm 29 ft lbf b ...

Page 1692: ... To prevent damage to the rotor shaft do not loosen the pulley nut more than one half of a turn f Remove the generator from SST C g Turn SST B and remove SST A and B h Remove the pulley nut and pulley 5 REMOVE RECTIFIER END FRAME a Remove the 4 nuts and wire clip b Using SST remove the rectifier end frame SST 09286 46011 c Remove the generator washer from the rotor 6 REMOVE ROTOR FROM DRIVE END FR...

Page 1693: ...gula tor b Using an ohmmeter check the continuity between termi nals F and E Standard When the positive and negative poles between termi nals F and E are exchanged there is continuity in one way but no continuity in another way If the continuity is not as specified replace the voltage regula tor 2 INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter check that there is continuity between the slip ring...

Page 1694: ...lace the drive end frame assembly 6 INSPECT STATOR DRIVE END FRAME FOR GROUND Using an ohmmeter check that there is no continuity between the coil lead and drive end frame If there is continuity replace the drive end frame assembly 7 INSPECT EXPOSED BRUSH LENGTH Using vernier calipers measure the exposed brush length Standard exposed length 9 5 11 5 mm 0 374 0 453 in Minimum exposed length 1 5 mm ...

Page 1695: ...ws continuity and the other shows no continuity If continuity is not as specified replace the rectifier holder 10 INSPECT FRONT BEARING Check that the bearing is not rough or worn 11 IF NECESSARY REPLACE FRONT BEARING a Remove the 4 screws bearing retainer and bearing b Using SST and a press press out the bearing SST 09950 60010 09951 00350 09950 70010 09951 07100 c Using SST and a press press in ...

Page 1696: ... 13 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing cover outside and bear ing SST 09820 00021 NOTICE Be careful not to damage the fan b Remove the bearing cover inside c Place the bearing cover inside on the rotor d Using SST and a press press in a new bearing SST 09820 00031 e Using SST push in the bearing cover outside SST 09285 76010 1695 ...

Page 1697: ...Place the generator washer on the rotor b Using a 29 mm socket wrench and press slowly press in the rectifier end frame c Install the wire clip and 4 nuts Torque Nut A 4 5 N m 46 kgf cm 40 in lbf Nut B 5 4 N m 55 kgf cm 48 in lbf 3 INSTALL PULLEY a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST A with a torque wrench and tighten SST B clockwise to the specifi...

Page 1698: ...he pulley nut turn SST A in the direction shown in the illustration Torque 111 N m 1 125 kgf cm 81 ft lbf g Remove the generator from SST C h Turn SST B and remove SST A and B 4 INSTALL RECTIFIER HOLDER a Install the 4 rubber insulators on the lead wires NOTICE Be careful of the rubber insulators installation direction b Install the rectifier holder while pushing it with the 4 screws Torque 2 9 N ...

Page 1699: ... NOTICE Be careful of the holder installation direction c Install the 5 screws Torque 2 0 N m 20 kgf cm 18 in lbf d Place the brush holder cover on the brush holder 6 INSTALL REAR END COVER a Install the end cover and plate terminal with the bolt and 3 nuts Torque Nut 4 4 N m 45 kgf cm 39 in lbf Bolt 3 9 N m 39 kgf cm 35 in lbf b Install the terminal insulator with the nut Torque 4 1 N m 42 kgf cm...

Page 1700: ...18 ft lbf 17 mm head 1ZZ FE 54 N m 550 kgf cm 40 ft lbf 2ZZ GE 58 N m 590 kgf cm 43 ft lbf b 2ZZ GE Install the generator bracket with the 2 bolts Torque 29 N m 295 kgf cm 21ft lbf c Connect the generator connector d Connect the generator wire and install the nut and rubber cap e Connect the generator wire and install the rubber cap and nut 2 INSTALL DRIVE BELT 1699 ...

Page 1701: ... 3 Release cylinder cup Damaged CL 4 CL 9 Clutch noisy 1 Release bearing Worn dirty or damaged 2 Clutch disc torsion rubber Damaged CL 14 CL 14 Clutch slips 1 Clutch pedal Free play out of adjustment 2 Clutch disc Oily 3 Clutch disc Worn out 4 Diaphragm spring Damaged 5 Pressure plate Distortion 6 Flywheel Distortion CL 2 CL 14 CL 14 CL 14 CL 14 Clutch does not disengage 1 Clutch pedal Free play o...

Page 1702: ...ittle Push rod play at pedal top 5 0 15 0 mm 0 197 0 591 in 4 IF NECESSARY ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY a Loosen the lock nut and turn the push rod until the free play and push rod play are correct b Tighten the lock nut c After adjusting the pedal free play check the pedal height 5 CHECK CLUTCH RELEASE POINT a Pull the parking brake lever and install wheel stopper b Start and idle the...

Page 1703: ...e does not start when the clutch ped al is released b Check that the engine starts when the clutch pedal is fully depressed If necessary replace the clutch start switch 7 INSPECT CLUTCH START SWITCH CONTINUITY Check the continuity between terminals when the switch is ON and OFF Switch position Condition ON pushed Continuity OFF free No continuity 1702 ...

Page 1704: ...ster Cylinder Clutch Line Reservoir Hose Slotted Spring Pin Grommet Non reusable part N m kgf cm ft lbf Specified torque 12 120 9 15 155 11 z Lock Nut 12 120 9 z Clip Lithium soap base glycol grease CL 4 CLUTCH CLUTCH MASTER CYLINDER 2005 CELICA RM1131U CLUTCH MASTER CYLINDER COMPONENTS 1703 ...

Page 1705: ... pliers disconnect the clip b Disconnect the reservoir hose from the inlet union c Use a container to catch the fluid 3 DISCONNECT CLUTCH LINE a Using SST disconnect the clutch line SST 09023 00101 b Use a container to catch the fluid 4 REMOVE CLIP AND PIN Using needle nose pliers remove the clip and pin 5 REMOVE 2 MOUNTING NUTS AND PULL OUT MAS TER CYLINDER 1704 ...

Page 1706: ...out the slotted spring pin b Remove the inlet union c Remove the grommet 2 REMOVE CLEVIS Loosen the lock nut to remove the clevis and remove the lock nut 3 REMOVE BOOT FROM CYLINDER 4 REMOVE PUSH ROD a While pushing the push rod using snap ring pliers re move the snap ring b Pull out the push rod and washer 5 REMOVE PISTON WITH SPRING FROM CYLINDER 1705 ...

Page 1707: ...STRATION 2 INSERT PISTON WITH SPRING INTO CYLINDER 3 INSTALL PUSH ROD a Install the washer to the push rod b Push the push rod into the piston using snap ring pliers install the snap ring 4 INSTALL BOOT TO CYLINDER 5 TEMPORARILY INSTALL LOCK NUT AND CLEVIS 6 INSTALL INLET UNION a Install a new grommet b Install the inlet union c Using a pin punch 3 mm and hammer drive in the slotted spring pin 170...

Page 1708: ...ECT CLUTCH LINE Using SST connect the clutch line SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 4 CONNECT RESERVOIR HOSE a Connect the reservoir hose to the inlet union NOTICE Facing the yellow mark upwards b Using pliers connect the clip 5 INSTALL BRAKE BOOSTER See page BR 18 6 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM See page BR 4 7 ADJUST CLUTCH PEDAL See page CL 2 8 C...

Page 1709: ...tch Line Clamp N m kgf cm ft lbf Specified torque Lithium soap base glycol grease Push Rod Boot Spring Clutch Line Piston 12 120 9 8 4 85 74 in lbf 15 155 11 4 9 50 43 in lbf CLUTCH CLUTCH RELEASE CYLINDER CL 9 2005 CELICA RM1131U CLUTCH RELEASE CYLINDER COMPONENTS 1708 ...

Page 1710: ...le is securely supported b Remove the LH and RH engine under covers c Using SST disconnect the clutch line SST 09023 00101 d Use a container to catch the fluid e Lower the vehicle 2 REMOVE RELEASE CYLINDER a Remove the air cleaner case assembly with the air hose b Remove the clutch line clamp set bolt c Remove the 2 bolts clutch line bracket and release cylin der 1709 ...

Page 1711: ...d b Remove the boot from the push rod 2 REMOVE PISTON AND SPRING Using compressed air remove the piston with the spring from the cylinder NOTICE S Blowing off the air may cause the piston s jump out When removing the piston hold it with your hand us ing a waste cloth S Take care not to splash brake fluid when air blowing 3 REMOVE BLEEDER PLUG 1710 ...

Page 1712: ...LY 1 INSTALL BLEEDER PLUG Torque 8 4 N m 85 kgf cm 74 in lbf 2 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 3 INSTALL PISTON AND SPRING INTO CYLINDER 4 INSTALL BOOT AND PUSH ROD a Install the push rod to the boot b Install the boot with the push rod to the cylinder 1711 ...

Page 1713: ...cket with the bolt Torque 4 9 N m 50 kgf cm 43 in lbf c Install the air cleaner case assembly with the air hose 2 CONNECT CLUTCH LINE AND BLEED CLUTCH SYS TEM a Raise the vehicle CAUTION Make sure that the vehicle is securely supported b Using SST connect the clutch line SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf c Fill the brake reservoir tank with brake fluid and bleed clutch system d Ch...

Page 1714: ... Clutch Cover Release Fork Boot Release Fork Support Release Bearing x 6 Clip 19 195 14 37 375 27 z Clutch spline grease Release hub grease See page CL 16 1st 49 500 36 2nd Turn 90 Non reusable part z CL 14 CLUTCH CLUTCH UNIT 2005 CELICA RM1131U CLUTCH UNIT COMPONENTS 1713 ...

Page 1715: ...mark on the clutch cover with the one on the flywheel b Loosen each set bolt one turn at a time until spring tension is released c Remove the set bolts and pull off the clutch cover with the clutch disc NOTICE Do not drop the clutch disc 3 REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them 4 REMOVE RELEASE FORK SUPPORT AND BOOT 1...

Page 1716: ...runout Maximum runout 0 8 mm 0 031 in If necessary replace the clutch disc runout 3 INSPECT FLYWHEEL RUNOUT Using a dial indicator check the flywheel runout Maximum runout 0 1 mm 0 004 in If necessary replace the flywheel HINT The flywheel bolts are tightened in 2 progressive steps 1 and 3 1 Install and uniformly tighten the 8 mounting bolts in several passes in the sequence shown Torque 49 N m 50...

Page 1717: ...ng for depth and width of wear Maximum A Depth 0 5 mm 0 020 in B Width 6 0 mm 0 236 in If necessary replace the clutch cover 5 INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direc tion HINT The bearing is permanently lubricated and requires no cleaning or lubrication If necessary replace the release bearing 1716 ...

Page 1718: ...the center tighten the bolts 2 CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument check the dia phragm spring tip alignment Maximum non alignment 0 5 mm 0 020 in If alignment is not as specified using SST adjust the dia phragm spring tip alignment SST 09333 00013 3 INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE Torque 37 N m 375 kgf cm 27 ft lbf 4 APPLY RELEASE ...

Page 1719: ...e 1 Oil Level low 2 Oil Wrong 3 Gear Worn or damaged 4 Bearing Worn or damaged MX 4 MX 4 MX 10 MX 10 Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn or damaged 4 O Ring Worn or damaged MX 4 MX 4 MX 4 MX 4 Hard to shift or will not shift 1 Control cable Faulty 2 Synchronizer ring Worn or damaged 3 Shifting key spring Damaged MX 53 MX 4 MX 30 MX 39 MX 4 MX 30 MX 39 Jumps out of gea...

Page 1720: ... lbf Specified torque 37 378 28 47 480 35 37 378 28 23 230 17 4 9 50 43 in lbf 12 120 9 4 9 50 43 in lbf 12 120 9 Clutch Release Cylinder Clutch Line Bracket Starter Starter Connector Starter Wire Radiator Reservoir Ground Cable Clip Washer Clamp Control Cable Bracket Wire Harness Back Up Light Switch Connector Speed Sensor Connector Wire Harness 64 650 47 ECM Outlet Duct 6 9 70 61 in lbf 7 0 71 6...

Page 1721: ...64 650 47 z 44 450 33 Gasket z Gasket z 43 440 32 7 8 80 69 in lbf 44 450 33 40 410 30 52 530 38 157 1 600 116 44 449 32 157 1 600 116 142 1 450 105 52 530 38 52 530 38 39 400 29 z Lock Nut 216 2 200 159 z Non reusable part For use with SST N m kgf cm ft lbf Specified torque Compression Spring Pipe 43 440 32 Oxygen Sensor 64 650 47 87 890 64 Pressure Feed and Return Tube z z 49 500 36 35 360 35 MA...

Page 1722: ...ND ECM BOX a Remove the 2 bolts and ECM cover Torque 6 9 N m 70 kgf cm 61 in lbf b Disconnect the ECM connectors from the ECM c Remove the ECM outlet duct d Remove the air cleaner case assembly with the air hose e Remove the 3 bolts and ECM box Torque 6 9 N m 70 kgf cm 61 in lbf f Disconnect the wire harness and remove the 2 nuts bolt and battery carrier Torque Bolt 18 N m 185 kgf cm 13 ft lbf Nut...

Page 1723: ...orque 37 N m 378 kgf cm 28 ft lbf 11 REMOVE CONTROL CABLE BRACKET a Disconnect the wire harness from the clamp b Remove the 2 bolts clamp and control cable bracket from the transaxle Torque 25 N m 250 kgf cm 18 ft lbf 12 REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque 64 N m 650 kgf cm 47 ft lbf 13 DISCONNECT RH AND LH TIE ROD ENDS See page SA 13 14 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY...

Page 1724: ...040 or 12281 15050 Bolt 91512 B1016 Torque 38 N m 387 kgf cm 28 ft lbf c Attach the engine chain hoist to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 18 REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque Bolt A 60 N m 610 kgf cm 44 ft lbf Nut B 80 N m 820 kgf cm 59 ft lbf 19 REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle ...

Page 1725: ... the front exhaust pipe from the pipe supports and remove it 25 DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM See page SA 43 26 DISCONNECT STABILIZER BAR LINK a Remove the nut and disconnect the stabilizer bar link Torque 44 N m 450 kgf cm 33 ft lbf b Employ the same manner described above to the other side 27 DISCONNECT ENGINE REAR MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Remove the bo...

Page 1726: ... and engine rear mounting bracket Torque 64 N m 650 kgf cm 47 ft lbf 32 JACK UP TRANSAXLE SLIGHTLY Using a transmission jack support the transaxle 33 REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS Torque Bolt A 47 N m 480 kgf cm 35 ft lbf Bolt B 23 N m 230 kgf cm 17 ft lbf 34 REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine HINT At the time of installation please ...

Page 1727: ...2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page MX 4 HINT After installation check and inspect items as follows S Bleed power steering system See page SR 4 S Front wheel alignment See page SA 5 S Do the road test 1726 ...

Page 1728: ...cm ft lbf Bearing Lock Plate Output Shaft Front Bearing Output Shaft Cover Oil Seal Magnet Transaxle Case 11 115 8 Clip z Vehicle Speed Sensor Control Cable Bracket 25 250 18 11 115 8 z Input Shaft Front Bearing z z 11 115 8 29 300 22 z MX 10 MANUAL TRANSAXLE C56 MANUAL TRANSAXLE ASSEMBLY 2005 CELICA RM1131U MANUAL TRANSAXLE ASSEMBLY COMPONENTS 1727 ...

Page 1729: ...Gear Reverse Idler Gear Shaft Output Shaft Assembly Snap Ring Input Shaft Assembly z Lock Nut Shifting Key Spring Spacer Needle Roller Bearing No 3 Shifting Key Snap Ring Rear Bearing Retainer 5th Gear No 3 Synchronizer Ring No 3 Hub Sleeve No 3 Clutch Hub x 5 L z Gasket Straight Screw Plug L L 16 160 12 L L L 17 175 13 Non reusable part Precoated part 25 250 18 16 160 12 25 250 18 16 160 12 25 25...

Page 1730: ... 13 z Gasket 39 400 29 Control Shift Lever Wave Washer 12 120 9 L 29 300 22 Control Bellcrank Dust Cover 12 120 9 Wave Washer Precoated part Non reusable part Selecting Bellcrank Assembly Control Shaft Assembly 25 250 18 Lever Lock Pin Dust Boot z Oil Seal 39 400 29 z Gasket 17 175 13 Straight Screw Plug L 13 130 9 12 120 9 Lock Ball Assembly Lock Ball Assembly Slotted Spring Pin Oil Receiver Pipe...

Page 1731: ...30 ft lbf 4 REMOVE CONTROL CABLE BRACKET Remove the 2 bolts and control cable bracket Torque 25 N m 250 kgf cm 18 ft lbf 5 REMOVE CONTROL SHAFT ASSEMBLY Remove the 2 nuts wave washer and control shaft assembly Torque 12 N m 120 kgf cm 9 ft lbf 6 REMOVE SELECTING BELLCRANK ASSEMBLY a Remove the 2 bolts and selecting bellcrank assembly Torque 25 N m 250 kgf cm 18 ft lbf NOTICE At the time of reassem...

Page 1732: ... the time of reassembly please refer to the following items S Install the dust boot into a groove in the control shift lever S Be sure to install the dust boot in the correct direc tion as shown in the illustration 8 REMOVE TRANSMISSION CASE COVER a Remove the 9 bolts Torque 18 N m 185 kgf cm 13 ft lbf b Using a brass bar and hammer carefully tap the projec tion of the transmission case cover to r...

Page 1733: ...refer to the following item Set the claws of the shift interlock plate into the shift head part of the gear shift fork shaft securely 11 REMOVE LOCK NUT a Engage the gear double meshing b Using a chisel and hammer loosen the staked part of the nut c Remove the lock nut Torque 118 N m 1 200 kgf cm 87 ft lbf d Disengage the gear double meshing 12 REMOVE NO 3 HUB SLEEVE AND NO 3 GEAR SHIFT FORK a Rem...

Page 1734: ...ift fork SST 09636 20010 NOTICE S Be sure to install the No 3 hub sleeve assembly in the correct direction as shown in the illustration S Align the No 3 synchronizer ring slots with the No 3 shifting keys 13 INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator measure the thrust clearance Standard clearance 0 10 0 57 mm 0 0039 0 0224 in Maximum clearance 0 57 mm 0 0224 in 14 INSPECT 5TH GEAR R...

Page 1735: ...5 0 1004 C 2 37 0 0933 G 2 61 0 1028 D 2 43 0 0957 b Using a screwdriver remove the shifting key spring from the No 3 clutch hub c Install a bolt and washer to the tip of the input shaft and using SST remove the No 3 clutch hub SST 09950 30012 HINT Select a bolt whose outer diameter is smaller than the screw hole of the input shaft so that it can be turned easily d Remove the No 3 synchronizer rin...

Page 1736: ...T AND GASKET Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 29 N m 300 kgf cm 22 ft lbf 20 REMOVE SNAP RING FROM NO 2 SHIFT FORK SHAFT Using 2 screwdrivers and a hammer tap out the snap ring 21 REMOVE STRAIGHT SCREW PLUG SEAT SPRING AND BALL a Using a hexagon wrench remove the 3 straight screw plugs Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent...

Page 1737: ...olts and oil receiver pipes from the transmission case Torque 17 N m 175 kgf cm 13 ft lbf NOTICE At the time of reassembly please refer to the following items S Prevent the oil receiver pipes from being deformed S Install the oil receiver pipes while placing it against the transmission case as shown in the illustration 25 REMOVE REVERSE IDLER GEAR THRUST WASHER AND SHAFT 26 REMOVE REVERSE SHIFT AR...

Page 1738: ...om each gear shift fork shaft b Remove the 3 bolts from the No 1 gear shift head No 1 and No 2 gear shift forks Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 16 N m 160 kgf cm 12 ft lbf c Pull up the No 3 gear shift fork shaft remove the No 2 gear shift fork shaft NOTICE At the time of reassembly please refer to the following item To avoid the interference of the 2 b...

Page 1739: ...FROM TRANSAXLE CASE 29 REMOVE DIFFERENTIAL CASE ASSEMBLY NOTICE At the time of reassembly please refer to the following item Before reassembly inspect the differential tapered roller bearing preload See page MX 50 30 REMOVE MAGNET FROM TRANSAXLE CASE 31 DISASSEMBLE NO 3 CLUTCH HUB ASSEMBLY a Using a screwdriver remove the shifting key spring NOTICE At the time of reassembly please refer to the fol...

Page 1740: ...synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 5 mm 0 020 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT GEAR SHIFT FORK AN...

Page 1741: ...P grease e Using SST and a press install a new input shaft front bearing SST 09950 60010 09951 00400 09950 70010 09951 07150 Drive in depth 0 0 3 mm 0 0 012 in NOTICE Be sure to install a new bearing in the correct direction as shown in the illustration 5 IF NECESSARY REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER a Remove the bolt and bearing lock plate b Using SST pull out the output ...

Page 1742: ... transaxle case receiver to the transaxle case with the bolt Torque 11 N m 115 kgf cm 8 ft lbf 7 IF NECESSARY REPLACE REVERSE RESTRICT PIN a Using a hexagon wrench remove the straight screw plug b Using a pin punch and hammer drive out the slotted spring pin c Replace the reverse restrict pin d Using a pin punch and hammer drive in the slotted spring pin e Apply sealant to the screw plug threads S...

Page 1743: ...in a new bushing SST 09950 60010 09951 00180 09950 70010 09951 07100 Drive in depth 0 80 1 30 mm 0 0315 0 0512 in 9 IF NECESSARY REPLACE TRANSMISSION CASE OIL SEAL a Using a screwdriver and hammer drive out the oil seal b Using a socket wrench 17 mm and plastic hammer drive in a new oil seal Drive in depth 10 0 0 3 mm 0 394 0 012 in c Coat the lip of the oil seal with MP grease 1742 ...

Page 1744: ... scraper remove all old FIPG material from the gasket surfaces S Thoroughly clean all components to remove all loose material S Clean both sealing surfaces with a non residue solvent S Apply FIPG in an approx 1 mm 0 04 in wide bead along the sealing surface S Parts must be assembled within 10 minutes of application Otherwise the FIPG material must be removed and reapplied HINT Coat all of the slid...

Page 1745: ...o 2 Hub Sleeve No 2 Synchronizer Ring For 4th Gear Snap Ring Rear Radial Ball Bearing 3rd Gear No 2 Shifting Key Spring No 2 Clutch Hub Needle Roller Bearing 4th Gear Snap Ring Spacer No 2 Shifting Key MANUAL TRANSAXLE C56 INPUT SHAFT MX 27 2005 CELICA RM1131U INPUT SHAFT COMPONENTS 1744 ...

Page 1746: ...t Standard clearance KOYO made 0 015 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 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 gear needle roller bearing or shaft 3 REMOVE SNAP RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the input...

Page 1747: ...O 2 HUB SLEEVE ASSEMBLY 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NEEDLE ROLLER BEARING a Using SST and a press remove the No 2 hub sleeve as sembly 3rd gear and No 2 synchronizer ring for the 3rd gear SST 09950 00020 HINT Support the input shaft by hand so that it will not be dropped off b Remove the needle roller bearings 7 DISASSEMBLE NO 2 HUB SLEEVE ASSEMBLY a Remove the No 2 hub sleeve...

Page 1748: ...s completely washed off after rubbing c Check again the braking effect of the synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 3rd gear 0 65 mm 0 0256 in 4th gear 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on g...

Page 1749: ...ameter of the in put shaft journal surface Minimum outer diameter Part A 24 885 mm 0 9797 in Part B 28 985 mm 1 1411 in Part C 30 985 mm 1 2199 in Part D 24 985 mm 0 9837 in If the outer diameter is less than the minimum replace the input shaft c Using a dial indicator check the shaft runout Maximum runout 0 03 mm 0 0012 in If the runout exceeds the maximum replace the input shaft 1748 ...

Page 1750: ...wn in the illustration 2 INSTALL NEEDLE ROLLER BEARING 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NO 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT a Apply gear oil to the needle roller bearings and install it b Install the 3rd gear and No 2 synchronizer ring for the 3rd gear NOTICE Distinguish the No 2 synchronizer ring for the 3rd gear by the teeth on the synchronizer ring c Install the No 2 hub sle...

Page 1751: ... See page MX 28 5 INSTALL SPACER NEEDLE ROLLER BEARING NO 2 SYNCHRONIZER RING FOR 4TH GEAR 4TH GEAR AND REAR RADIAL BALL BEARING a Install the spacer b Apply gear oil to the needle roller bearings and install it c Place the No 2 synchronizer ring for the 4th gear on the No 2 hub sleeve assembly and align the No 2 synchro nizer ring slots with the No 2 shifting keys d Install the 4th gear NOTICE Di...

Page 1752: ...e of the rear radial ball bearing less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in A 2 29 0 0902 D 2 47 0 0972 B 2 35 0 0925 E 2 53 0 0996 C 2 41 0 0949 F 2 59 0 1020 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the input shaft 7 INSPECT 4TH GEAR THRUST CLEARANCE See page MX 28 1751 ...

Page 1753: ...ar No 1 Clutch Hub No 1 Shifting Key Spring Reverse Gear Snap Ring Output Gear Spacer No 2 Synchronizer Ring Rear Radial Ball Bearing Needle Roller Bearing 3rd Driven Gear 4th Driven Gear 2nd Gear Spacer Snap Ring Front Bearing Inner Race MANUAL TRANSAXLE C56 OUTPUT SHAFT MX 35 2005 CELICA RM1131U OUTPUT SHAFT COMPONENTS 1752 ...

Page 1754: ...a dial indicator measure the radial clearance between the gear and shaft Standard clearance KOYO made 0 015 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 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 gear needle roller bearing or shaft 3 REMOVE REAR RADIAL BALL BEARING 4TH DRIV EN GEAR AND OUTPUT GEA...

Page 1755: ... RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the output shaft 6 REMOVE REVERSE GEAR ASSEMBLY 1ST GEAR NO 1 SYNCHRONIZER RING NEEDLE ROLLER BEARING 1ST GEAR THRUST WASHER AND BALL a Using a press remove the reverse gear assembly 1st gear and No 1 synchronizer ring HINT Support the output shaft assembly by hand so that it will not ...

Page 1756: ...ST 09950 00020 NOTICE When replacing the front bearing inner race replace the output shaft front bearing along with it HINT Support the output shaft by hand so that it will not be dropped off 9 DISASSEMBLE REVERSE GEAR ASSEMBLY a Remove the reverse gear from the No 1 clutch hub b Remove the 3 No 1 shifting keys and No 1 shifting key springs from the No 1 clutch hub 1755 ...

Page 1757: ... Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT 2ND GEAR SYNCHRONIZER RING a Check ...

Page 1758: ...e the gear shift fork or hub sleeve 4 INSPECT OUTPUT SHAFT a Check the output shaft for wear or damage b Using a micrometer measure the outer diameter of the output shaft journal surface Minimum outer diameter Part A 32 985 mm 1 2986 in Part B 37 985 mm 1 4955 in Part C 31 985 mm 1 2592 in If the outer diameter is less than the minimum replace the out put shaft c Using a dial indicator check the s...

Page 1759: ... the table below that will make the thrust clearance of the front bearing inner race less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in 7 1 85 0 0728 3 2 05 0 0807 8 1 90 0 0748 4 2 10 0 0827 1 1 95 0 0768 5 2 15 0 0846 2 2 00 0 0787 6 2 20 0 0866 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the output shaft 3 ASSEMBLE ...

Page 1760: ...the No 1 synchronizer ring by the teeth on the synchronizer ring e Place the reverse gear assembly and align the No 1 syn chronizer ring slots with the No 1 shifting keys f Using a press install the reverse gear assembly NOTICE S Be sure to install the reverse gear assembly in the correct direction as shown in the illustration S When installing make sure that the ball is placed in a groove of the ...

Page 1761: ...l it c Place the No 2 synchronizer rings on the 2nd gear NOTICE S Properly fit the synchronizer middle ring claws into the holes in the 2nd gear S Distinguish the No 2 synchronizer ring by the teeth on the synchronizer ring d Place the 2nd gear with the No 2 synchronizer rings and align the No 2 synchronizer ring slots with the No 1 shift ing keys NOTICE Fit the synchronizer inner ring claws into ...

Page 1762: ...IAL BALL BEARING a Install the output gear spacer b Using SST and a press install the 4th driven gear and rear radial ball bearing SST 09608 00071 NOTICE Be sure to install the 4th driven gear and rear radial ball bearing in the correct direction as shown in the illustra tion HINT Set SST to the bearing inner race securely 1761 ...

Page 1763: ...on Spring Snap Ring Shift and Select Lever Shaft No 1 Select Spring Seat Slotted Spring Pin Slotted Spring Pin No 1 Shift Inner Lever Slotted Spring Pin Compression Spring E Ring Apply MP grease MANUAL TRANSAXLE C56 SHIFTAND SELECT LEVER SHAFT MX 45 2005 CELICA RM1131U SHIFT AND SELECT LEVER SHAFT COMPONENTS 1762 ...

Page 1764: ...gf cm ft lbf Specified torque z x 8 z Oil Seal Transaxle Case Vehicle Speed Sensor Drive Gear 77 790 57 Straight Pin Differential Case z Tapered Roller Bearing and Outer Race z Oil Seal Transmission Case Spacer Apply MP grease Non reusable part MX 46 MANUAL TRANSAXLE C56 DIFFERENTIAL CASE 2005 CELICA RM1131U DIFFERENTIAL CASE COMPONENTS 1763 ...

Page 1765: ...icle speed sensor drive gear 3 Ring gear side REMOVE TAPERED ROLLER BEARING FROM DIF FERENTIAL CASE Using SST remove the tapered roller bearing SST 09950 40011 09950 60010 09951 00350 HINT Set the claw of SST to the bearing inner race at the position where the differential case is indented 4 INSPECT SIDE GEAR BACKLASH Using a dial indicator measure the backlash of one side gear while holding one p...

Page 1766: ...ing SST and a hammer drive in a new oil seal SST 09226 10010 Drive in depth 9 9 0 3 mm 0 390 0 012 in d Coat the lip of the oil seal with MP grease e Place the shim into the differential case f Using SST and a press install the tapered roller bearing outer race SST 09950 60020 09951 00710 09950 70010 09951 07150 NOTICE When replacing the tapered roller bearing outer race re place the tapered rolle...

Page 1767: ...he differential case d Using SST and a press install the tapered roller bearing outer race SST 09950 60020 09951 00680 09950 70010 09951 07150 NOTICE When replacing the tapered roller bearing outer race re place the tapered roller bearing along with it e Using SST and a hammer drive in a new oil seal SST 09710 28021 09710 08041 Drive in depth 1 9 0 3 mm 0 075 0 012 in f Coat the lip of the oil sea...

Page 1768: ... d Using a dial indicator check the side gear backlash Measure the side gear backlash while holding one pinion toward the differential case Standard backlash 0 05 0 20 mm 0 0020 0 0079 in If the backlash is not within the specification install a thrust washer of different thickness e Using a pin punch and hammer drive in the straight pin through the differential case and hole in the pinion shaft f...

Page 1769: ...n the contact surface of the differential case b Heat the ring gear in boiling water c Carefully take the ring gear out of the water d After the moisture on the ring gear has completely evapo rated quickly install the ring gear to the differential case HINT Align the matchmarks on the differential case and contact the ring gear e Temporarily install the 8 set bolts CAUTION The ring gear set bolts ...

Page 1770: ... trans mission case side outer race of the tapered roller bearing with SST See page MX 47 Select an appropriate shim HINT The preload will change by about 0 3 0 4 N m 3 4 kgf cm 2 6 3 5 in lbf corresponding to a change of 0 05 mm 0 0020 in in shim thickness Mark Thickness mm in Mark Thickness mm in AA 2 10 0 0827 LL 2 60 0 1024 BB 2 15 0 0846 MM 2 65 0 1043 CC 2 20 0 0866 NN 2 70 0 1063 DD 2 25 0 ...

Page 1771: ...dlight Dimmer Switch Lower Column Cover Front Pillar Garnish Steering Wheel Airbag Sensor Assembly Junction Block Shift Lever Knob Upper Console Panel w Power window Power Window Switch Radio Steering Wheel Pad Junction Block RH End Finish Panel Heater Control and Accessory Assembly Console Box Front Door Opening Trim Cowl Side Trim LH End Finish Panel Door Scuff Plate Clock 20 204 15 20 205 15 34...

Page 1772: ...anel Reinforcement Heater Hose Non reusable part A C Unit Blower Unit Clamp z O Ring Liquid Tube Suction Tube Clamp No 1 Brace No 2 Brace z MX 54 MANUAL TRANSAXLE C56 SHIFT LEVER AND CONTROL CABLE 2005 CELICA RM1131U 1771 ...

Page 1773: ...ip Clip Select Control Cable Washer Clip Shift Lever Assembly Shift Cable Retainer Grommet Bracket Clip Washer Clip Specified torque ECM Connector ECM Outlet Duct 6 9 70 61 in lbf 6 9 70 61 in lbf 12 120 9 4 9 50 43 in lbf 4 9 50 43 in lbf N m kgf cm ft lbf MANUAL TRANSAXLE C56 SHIFT LEVER AND CONTROL CABLE MX 55 2005 CELICA RM1131U 1772 ...

Page 1774: ...X 4 MX 10 MX 10 Oil leakage 1 Oil Level too high 2 Gasket Damaged 3 Oil seal Worn or damaged 4 O Ring Worn or damaged MX 4 MX 10 MX 10 MX 10 Hard to shift or will not shift 1 Control cable Faulty 2 Synchronizer ring Worn or damaged 3 Shifting key spring Damaged MX 58 MX 25 MX 33 MX 42 MX 25 MX 33 MX 42 Jumps out of gear 1 Locking ball spring Damaged 2 Gear shift fork Worn 3 Gear Worn or damaged 4 ...

Page 1775: ... Transaxle N m kgf cm ft lbf Specified torque 37 378 28 47 480 35 37 378 28 23 230 17 4 9 50 43 in lbf 12 120 9 4 9 50 43 in lbf 12 120 9 Clutch Release Cylinder Clutch Line Bracket Starter Starter Connector Starter Wire Radiator Reservoir Ground Cable Clip Washer Clamp Control Cable Bracket Wire Harness Back Up Light Switch Connector Speed Sensor Connector Wire Harness 64 650 47 ECM Outlet Duct 6...

Page 1776: ...64 650 47 z 44 450 33 Gasket z Gasket z 43 440 32 7 8 80 69 in lbf 44 450 33 40 410 30 52 530 38 157 1 600 116 44 449 32 157 1 600 116 142 1 450 105 52 530 38 52 530 38 39 400 29 z Lock Nut 216 2 200 159 z Non reusable part For use with SST N m kgf cm ft lbf Specified torque Compression Spring Pipe 43 440 32 Oxygen Sensor 64 650 47 87 890 64 Pressure Feed and Return Tube z z 49 500 36 35 360 35 MA...

Page 1777: ...M BOX a Remove the 2 bolts and ECM cover Torque 6 9 N m 70 kgf cm 61 in lbf b Disconnect the ECM connectors from the ECM c Remove the ECM outlet duct d Remove the air cleaner case assembly with the air hose e Remove the 3 bolts and ECM box Torque 6 9 N m 70 kgf cm 61 in lbf f Disconnect the wire harness and remove the 2 nuts bolt and battery carrier Torque Bolt 18 N m 185 kgf cm 13 ft lbf Nut 12 N...

Page 1778: ...orque 37 N m 378 kgf cm 28 ft lbf 11 REMOVE CONTROL CABLE BRACKET a Disconnect the wire harness from the clamp b Remove the 2 bolts clamp and control cable bracket from the transaxle Torque 25 N m 250 kgf cm 18 ft lbf 12 REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque 64 N m 650 kgf cm 47 ft lbf 13 DISCONNECT RH AND LH TIE ROD ENDS See page SA 13 14 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY...

Page 1779: ...12282 88600 Bolt 91512 61020 Torque 38 N m 387 kgf cm 28 ft lbf c Attach the engine chain hoist to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 18 REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET BOLTS AND NUT Torque Bolt A 60 N m 610 kgf cm 44 ft lbf Nut B 80 N m 820 kgf cm 59 ft lbf 19 REMOVE ENGINE LEFT MOUNTING BRACKET Lower the transaxle side an...

Page 1780: ... the front exhaust pipe from the pipe supports and remove it 25 DISCONNECT LOWER BALL JOINT FROM LOWER SUSPENSION ARM See page SA 43 26 DISCONNECT STABILIZER BAR LINK a Remove the nut and disconnect the stabilizer bar link Torque 44 N m 450 kgf cm 33 ft lbf b Employ the same manner described above to the other side 27 DISCONNECT ENGINE REAR MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Remove the bo...

Page 1781: ... and engine rear mounting bracket Torque 64 N m 650 kgf cm 47 ft lbf 32 JACK UP TRANSAXLE SLIGHTLY Using a transmission jack support the transaxle 33 REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS Torque Bolt A 47 N m 480 kgf cm 35 ft lbf Bolt B 23 N m 230 kgf cm 17 ft lbf 34 REMOVE TRANSAXLE Lower the engine left side and remove the transaxle from the engine HINT At the time of installation please ...

Page 1782: ...2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page MX 4 HINT After installation check and inspect items as follows S Bleed power steering system See page SR 4 S Front wheel alignment See page SA 5 S Do the road test 1781 ...

Page 1783: ...cm ft lbf Bearing Lock Plate Output Shaft Front Bearing Output Shaft Cover Oil Seal Magnet Transaxle Case 11 115 8 Clip z Vehicle Speed Sensor Control Cable Bracket 25 250 18 11 115 8 z Input Shaft Front Bearing z z 11 115 8 29 300 22 z MX 10 MANUAL TRANSAXLE C60 MANUAL TRANSAXLE ASSEMBLY 2005 CELICA RM1131U MANUAL TRANSAXLE ASSEMBLY COMPONENTS 1782 ...

Page 1784: ...y Input Shaft Assembly Shifting Key Spring Input Shaft Rear Radial Ball Bearing No 1 Gear Shift Fork Thrust Washer x 5 Snap Ring No 3 Gear Shift Fork Snap Ring 6th Driven Gear Snap Ring Snap Ring Snap Ring Spacer Snap Ring No 3 Shifting Key 5th Gear Shifting Key Spring No 3 Clutch Hub 6th Gear z Specified torque N m kgf cm ft lbf L L Snap Ring L L Spacer L L L L L No 3 Synchronizer Ring For 6th Ge...

Page 1785: ...pring Seat z Gasket Control Shaft Cover L 20 200 14 Compression Spring Compression Spring Select Spring Seat 18 185 13 z Gasket 39 400 29 Control Shift Lever Wave Washer 12 120 9 L 29 300 22 29 300 22 Control Bellcrank Dust Cover 12 120 9 Wave Washer Precoated part Non reusable part Selecting Bellcrank Assembly Control Shaft Assembly 25 250 18 Lever Lock Pin Dust Boot z Oil Seal Gasket 39 400 29 z...

Page 1786: ...30 ft lbf 4 REMOVE CONTROL CABLE BRACKET Remove the 2 bolts and control cable bracket Torque 25 N m 250 kgf cm 18 ft lbf 5 REMOVE CONTROL SHAFT ASSEMBLY Remove the 2 nuts wave washer and control shaft assembly Torque 12 N m 120 kgf cm 9 ft lbf 6 REMOVE SELECTING BELLCRANK ASSEMBLY a Remove the 2 bolts and selecting bellcrank assembly Torque 25 N m 250 kgf cm 18 ft lbf NOTICE At the time of reassem...

Page 1787: ...assembly please refer to the following items S Install the dust boot into a groove in the control shift lever S Be sure to install the dust boot in the correct direc tion as shown in the illustration 8 REMOVE PLUG LOCK BALL ASSEMBLY AND CON TROL SHAFT COVER ASSEMBLY a Using a hexagon wrench remove the plug and gasket Torque 39 N m 400 kgf cm 29 ft lbf b Remove the lock ball assembly Sealant Part N...

Page 1788: ... gear shift fork shaft securely b Remove the select spring seat and compression spring from the shift and select lever shaft assembly 11 REMOVE TRANSMISSION CASE COVER a Remove the 9 bolts Torque 18 N m 185 kgf cm 13 ft lbf b Carefully tap the projection of the transmission case cov er with a brass bar and hammer and remove it HINT At the time of reassembly please refer to the following item Apply...

Page 1789: ...ing item Select a snap ring from the table below that will make the thrust clearance of the output shaft rear radial ball bearing less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in B 2 31 0 0909 H 2 67 0 1051 C 2 37 0 0933 J 2 73 0 1075 D 2 43 0 0957 K 2 79 0 1098 E 2 49 0 0980 L 2 85 0 1122 F 2 55 0 1004 M 2 91 0 1146 G 2 61 0 1028 b Using SST remove the rear radial ball bearing...

Page 1790: ...ill make the thrust clearance of the No 3 clutch hub less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in A 1 70 0 0669 G 2 00 0 0787 B 1 75 0 0689 H 2 05 0 0807 C 1 80 0 0709 J 2 10 0 0827 D 1 85 0 0728 K 2 15 0 0846 E 1 90 0 0748 L 2 20 0 0866 F 1 95 0 0768 M 2 25 0 0886 b Using SST remove the rear radial ball bearing and 6th gear SST 09950 40011 09951 04010 09952 04010 09953 040...

Page 1791: ...K AND NO 3 HUB SLEEVE Remove the bolt No 3 gear shift fork and No 3 hub sleeve Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 16 N m 160 kgf cm 12 ft lbf 18 INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator measure the thrust clearance Standard clearance 0 10 0 62 mm 0 0039 0 0244 in Maximum clearance 0 62 mm 0 0244 in 19 INSPECT 5TH GEAR RADIAL CLEARANCE Using...

Page 1792: ...0846 E 1 95 0 0768 b Using SST remove the No 3 clutch hub assembly SST 09950 30012 09951 03010 09953 03010 09950 50013 09954 05031 HINT At the time of reassembly please refer to the following items S Before driving in the No 3 clutch hub assembly and input shaft rear radial ball bearing place the suitable sized wooden block on the rear side of the input shaft as shown in the illustration When driv...

Page 1793: ...the needle roller bearing and 2 spacers 21 REMOVE 5TH DRIVEN GEAR Using SST remove the 5th driven gear SST 09950 30012 09951 03010 09953 03010 09954 03010 09955 03021 HINT At the time of reassembly please refer to the following item Using SST and a hammer drive in the 5th driven gear SST 09612 22011 22 REMOVE REAR BEARING RETAINER Remove the 5 bolts and rear bearing retainer Sealant Part No 08833 ...

Page 1794: ...EE BOND 1344 LOCTITE 242 or equivalent Torque 25 N m 250 kgf cm 18 ft lbf b Using a magnetic finger remove the 3 seats springs and balls 27 REMOVE STRAIGHT SCREW PLUG Using a hexagon wrench remove the 2 straight screw plugs Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque Plug A 13 N m 130 kgf cm 9 ft lbf Plug B 39 N m 400 kgf cm 29 ft lbf 28 REMOVE TRANSMISSION CASE a ...

Page 1795: ...HIFT ARM BRACKET Remove the 2 bolts and reverse shift arm bracket Torque 17 N m 175 kgf cm 13 ft lbf NOTICE At the time of reassembly please refer to the following items S Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear S Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing 31 REMOVE REVERSE IDLER GEAR THRUST WASHER A...

Page 1796: ...ICE At the time of reassembly please refer to the following item Make sure that the 3 gear shift heads are positioned as shown in the illustration 34 REMOVE NO 2 GEAR SHIFT FORK SHAFT Remove the No 2 gear shift fork shaft from the No 2 gear shift fork No 1 gear shift head No 1 gear shift fork reverse shift fork and transaxle case 35 REMOVE NO 1 GEAR SHIFT FORK SHAFT Remove the No 1 gear shift fork...

Page 1797: ...E 40 REMOVE INPUT AND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 41 REMOVE DIFFERENTIAL CASE ASSEMBLY NOTICE At the time of reassembly please refer to the following item Before reassembly inspect the differential tapered roller bearing preload See page MX 53 42 REMOVE MAGNET FROM TRANSAXLE CASE 43 DISASSEMBLE NO 3 CLUTCH HUB ASSEMBLY a Using a screwdriver remove the 2 shifting key springs NOTICE A...

Page 1798: ...he synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT GEAR SHIFT FO...

Page 1799: ...P grease e Using SST and a press install a new input shaft front bearing SST 09950 60010 09951 00400 09950 70010 09951 07150 Drive in depth 0 0 3 mm 0 0 012 in NOTICE Be sure to install a new bearing in the correct direction as shown in the illustration 5 IF NECESSARY REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER a Remove the bolt and bearing lock plate b Using SST pull out the output ...

Page 1800: ... cm 8 ft lbf 6 INSTALL TRANSAXLE CASE RECEIVER Install the transaxle case receiver to the transaxle case with the bolt Torque 11 N m 115 kgf cm 8 ft lbf 7 IF NECESSARY REPLACE TRANSMISSION CASE BUSHING a Using a socket wrench 12 mm extension bar and plastic hammer drive out the bushing NOTICE When driving out the bushing be careful not to damage the transmission case by the socket wrench b Using S...

Page 1801: ... 3 mm MX 28 MANUAL TRANSAXLE C60 MANUAL TRANSAXLE ASSEMBLY 2005 CELICA RM1131U b Using a socket wrench 17 mm and plastic hammer drive in a new oil seal Drive in depth 10 0 0 3 mm 0 394 0 012 in c Coat the lip of the oil seal with MP grease 1800 ...

Page 1802: ... scraper remove all old FIPG material from the gasket surfaces S Thoroughly clean all components to remove all loose material S Clean both sealing surfaces with a non residue solvent S Apply FIPG in an approx 1 mm 0 04 in wide bead along the sealing surface S Parts must be assembled within 10 minutes of application Otherwise the FIPG material must be removed and reapplied HINT Coat all of the slid...

Page 1803: ... 2 Hub Sleeve No 2 Synchronizer Ring For 4th Gear Snap Ring Center Radial Ball Bearing 3rd Gear No 2 Shifting Key Spring No 2 Clutch Hub Needle Roller Bearing 4th Gear Snap Ring Spacer No 2 Shifting Key MX 30 MANUAL TRANSAXLE C60 INPUT SHAFT 2005 CELICA RM1131U INPUT SHAFT COMPONENTS 1802 ...

Page 1804: ... Standard clearance KOYO made 0 015 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 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 gear needle roller bearing or shaft 3 REMOVE SNAP RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the input ...

Page 1805: ...O 2 HUB SLEEVE ASSEMBLY 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NEEDLE ROLLER BEARING a Using SST and a press remove the No 2 hub sleeve as sembly 3rd gear and No 2 synchronizer ring for the 3rd gear SST 09950 00020 HINT Support the input shaft by hand so that it will not be dropped off b Remove the needle roller bearings 7 DISASSEMBLE NO 2 HUB SLEEVE ASSEMBLY a Remove the No 2 hub sleeve...

Page 1806: ...s completely washed off after rubbing c Check again the braking effect of the synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 3rd gear 0 65 mm 0 0256 in 4th gear 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on g...

Page 1807: ...e in put shaft journal surface Minimum outer diameter Part A 21 991 mm 0 8658 in Part B 24 885 mm 0 9797 in Part C 28 985 mm 1 1411 in Part D 30 985 mm 1 2199 in Part E 24 985 mm 0 9837 in If the outer diameter is less than the minimum replace the input shaft c Using a dial indicator check the shaft runout Maximum runout 0 03 mm 0 0012 in If the runout exceeds the maximum replace the input shaft 1...

Page 1808: ...wn in the illustration 2 INSTALL NEEDLE ROLLER BEARING 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NO 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT a Apply gear oil to the needle roller bearings and install it b Install the 3rd gear and No 2 synchronizer ring for the 3rd gear NOTICE Distinguish the No 2 synchronizer ring for the 3rd gear by the teeth on the synchronizer ring c Install the No 2 hub sle...

Page 1809: ... page MX 31 5 INSTALL SPACER NEEDLE ROLLER BEARING NO 2 SYNCHRONIZER RING FOR 4TH GEAR 4TH GEAR AND CENTER RADIAL BALL BEARING a Install the spacer b Apply gear oil to the needle roller bearings and install it c Place the No 2 synchronizer ring for the 4th gear on the No 2 hub sleeve assembly and align the No 2 synchro nizer ring slots with the No 2 shifting keys d Install the 4th gear NOTICE Dist...

Page 1810: ... of the center radial ball bearing less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in A 2 29 0 0902 D 2 47 0 0972 B 2 35 0 0925 E 2 53 0 0996 C 2 41 0 0949 F 2 59 0 1020 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the input shaft 7 INSPECT 4TH GEAR THRUST CLEARANCE See page MX 31 1809 ...

Page 1811: ...r No 1 Clutch Hub No 1 Shifting Key Spring Reverse Gear Snap Ring Output Gear Spacer No 2 Synchronizer Ring Center Radial Ball Bearing Needle Roller Bearing 3rd Driven Gear 4th Driven Gear 2nd Gear Spacer Snap Ring Front Bearing Inner Race MX 38 MANUAL TRANSAXLE C60 OUTPUT SHAFT 2005 CELICA RM1131U OUTPUT SHAFT COMPONENTS 1810 ...

Page 1812: ... dial indicator measure the radial clearance between the gear and shaft Standard clearance KOYO made 0 015 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 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 gear needle roller bearing or shaft 3 REMOVE CENTER RADIAL BALL BEARING 4TH DRIVEN GEAR AND OUTPUT GEA...

Page 1813: ... RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the output shaft 6 REMOVE REVERSE GEAR ASSEMBLY 1ST GEAR NO 1 SYNCHRONIZER RING NEEDLE ROLLER BEARING 1ST GEAR THRUST WASHER AND BALL a Using a press remove the reverse gear assembly 1st gear and No 1 synchronizer ring HINT Support the output shaft assembly by hand so that it will not ...

Page 1814: ...ST 09950 00020 NOTICE When replacing the front bearing inner race replace the output shaft front bearing along with it HINT Support the output shaft by hand so that it will not be dropped off 9 DISASSEMBLE REVERSE GEAR ASSEMBLY a Remove the reverse gear from the No 1 clutch hub b Remove the 3 No 1 shifting keys and No 1 shifting key springs from the No 1 clutch hub 1813 ...

Page 1815: ... Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT 2ND GEAR SYNCHRONIZER RING a Check ...

Page 1816: ...e the gear shift fork or hub sleeve 4 INSPECT OUTPUT SHAFT a Check the output shaft for wear or damage b Using a micrometer measure the outer diameter of the output shaft journal surface Minimum outer diameter Part A 32 985 mm 1 2986 in Part B 37 985 mm 1 4955 in Part C 31 985 mm 1 2592 in If the outer diameter is less than the minimum replace the out put shaft c Using a dial indicator check the s...

Page 1817: ... the table below that will make the thrust clearance of the front bearing inner race less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thickness mm in 7 1 85 0 0728 3 2 05 0 0807 8 1 90 0 0748 4 2 10 0 0827 1 1 95 0 0768 5 2 15 0 0846 2 2 00 0 0787 6 2 20 0 0866 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the output shaft 3 ASSEMBLE ...

Page 1818: ...the No 1 synchronizer ring by the teeth on the synchronizer ring e Place the reverse gear assembly and align the No 1 syn chronizer ring slots with the No 1 shifting keys f Using a press install the reverse gear assembly NOTICE S Be sure to install the reverse gear assembly in the correct direction as shown in the illustration S When installing make sure that the ball is placed in a groove of the ...

Page 1819: ...l it c Place the No 2 synchronizer rings on the 2nd gear NOTICE S Properly fit the synchronizer middle ring claws into the holes in the 2nd gear S Distinguish the No 2 synchronizer ring by the teeth on the synchronizer ring d Place the 2nd gear with the No 2 synchronizer rings and align the No 2 synchronizer ring slots with the No 1 shift ing keys NOTICE Fit the synchronizer inner ring claws into ...

Page 1820: ...AL BALL BEARING a Install the output gear spacer b Using SST and a press install the 4th driven gear and center radial ball bearing SST 09608 00071 NOTICE Be sure to install the 4th driven gear and center radial ball bearing in the correct direction as shown in the illustra tion HINT Set SST to the bearing inner race securely 1819 ...

Page 1821: ...Compression Spring Slotted Spring Pin No 2 Shift Inner Lever Slotted Spring Pin Apply MP grease E Ring No 1 Shift Inner Lever No 2 Select Spring Seat MX 48 MANUAL TRANSAXLE C60 SHIFTAND SELECT LEVER SHAFT 2005 CELICA RM1131U SHIFT AND SELECT LEVER SHAFT COMPONENTS 1820 ...

Page 1822: ...gf cm ft lbf Specified torque z x 8 z Oil Seal Transaxle Case Vehicle Speed Sensor Drive Gear 77 790 57 Straight Pin Differential Case z Tapered Roller Bearing and Outer Race z Oil Seal Transmission Case Spacer Non reusable part Apply MP grease MANUAL TRANSAXLE C60 DIFFERENTIAL CASE MX 49 2005 CELICA RM1131U DIFFERENTIAL CASE COMPONENTS 1821 ...

Page 1823: ...t the claw of SST to the bearing inner race securely b Remove the vehicle speed sensor drive gear 3 Ring gear side REMOVE TAPERED ROLLER BEARING FROM DIF FERENTIAL CASE Using SST remove the tapered roller bearing SST 09950 40011 09951 04010 09952 04010 09953 04020 09954 04010 09955 04061 09957 04010 09958 04011 09950 60010 09951 00350 HINT Set the claw of SST to the bearing inner race at the posit...

Page 1824: ...D ROLLER BEARING OUTER RACE a Using SST pull out the tapered roller bearing outer race and shim SST 09612 65014 b Using SST and a hammer drive out the oil seal SST 09226 10010 c Using SST and a hammer drive in a new oil seal SST 09226 10010 Drive in depth 9 9 0 3 mm 0 390 0 012 in d Coat the lip of the oil seal with MP grease e Place the shim into the differential case f Using SST and a press inst...

Page 1825: ...oller bearing outer race and spacer SST 09612 65014 c Place the spacer into the differential case d Using SST and a press install the tapered roller bearing outer race SST 09950 60020 09951 00680 09950 70010 09951 07150 NOTICE When replacing the tapered roller bearing outer race re place the tapered roller bearing along with it e Using SST and a hammer drive in a new oil seal SST 09710 28021 09710...

Page 1826: ... d Using a dial indicator check the side gear backlash Measure the side gear backlash while holding one pinion toward the differential case Standard backlash 0 05 0 20 mm 0 0020 0 0079 in If the backlash is not within the specification install a thrust washer of different thickness e Using a pin punch and hammer drive in the straight pin through the differential case and hole in the pinion shaft f...

Page 1827: ...n the contact surface of the differential case b Heat the ring gear in boiling water c Carefully take the ring gear out of the water d After the moisture on the ring gear has completely evapo rated quickly install the ring gear to the differential case HINT Align the matchmarks on the differential case and contact the ring gear e Temporarily install the 8 set bolts CAUTION The ring gear set bolts ...

Page 1828: ... trans mission case side outer race of the tapered roller bearing with SST See page MX 50 Select an appropriate shim HINT The preload will change by about 0 3 0 4 N m 3 4 kgf cm 2 6 3 5 in lbf corresponding to a change of 0 05 mm 0 0020 in in shim thickness Mark Thickness mm in Mark Thickness mm in AA 2 10 0 0827 LL 2 60 0 1024 BB 2 15 0 0846 MM 2 65 0 1043 CC 2 20 0 0866 NN 2 70 0 1063 DD 2 25 0 ...

Page 1829: ...4 D07704 Back Up Light Switch Combination Meter Reverse Shift Warning Buzzer MX 56 MANUAL TRANSAXLE C60 REVERSE SHIFT WARNING BUZZER SYSTEM 2005 CELICA RM1131U REVERSE SHIFT WARNING BUZZER SYSTEM LOCATION 1828 ...

Page 1830: ...UAL TRANSAXLE C60 REVERSE SHIFT WARNING BUZZER SYSTEM MX 57 2005 CELICA RM1131U INSPECTION 1 INSPECT REVERSE SHIFT WARNING BUZZER SYSTEM See page BE 50 2 INSPECT BACK UP LIGHT SWITCH CONTINUITY See page BE 34 1829 ...

Page 1831: ...dlight Dimmer Switch Lower Column Cover Front Pillar Garnish Steering Wheel Airbag Sensor Assembly Junction Block Shift Lever Knob Upper Console Panel w Power window Power Window Switch Radio Steering Wheel Pad Junction Block RH End Finish Panel Heater Control and Accessory Assembly Console Box Front Door Opening Trim Cowl Side Trim LH End Finish Panel Door Scuff Plate Clock 20 204 15 20 205 15 34...

Page 1832: ...anel Reinforcement Heater Hose Non reusable part A C Unit Blower Unit Clamp z O Ring Liquid Tube Suction Tube Clamp No 1 Brace No 2 Brace z MANUAL TRANSAXLE C60 SHIFT LEVER AND CONTROL CABLE MX 59 2005 CELICA RM1131U 1831 ...

Page 1833: ...ip Clip Select Control Cable Washer Clip Shift Lever Assembly Shift Cable Retainer Grommet Bracket Clip Washer Clip Specified torque ECM Connector ECM Outlet Duct 6 9 70 61 in lbf 6 9 70 61 in lbf 12 120 9 4 9 50 43 in lbf 4 9 50 43 in lbf N m kgf cm ft lbf MX 60 MANUAL TRANSAXLE C60 SHIFT LEVER AND CONTROL CABLE 2005 CELICA RM1131U 1832 ...

Page 1834: ...IC TRANSAXLE U240E AUTOMATIC TRANSAXLE SYSTEM AX 1 2005 CELICA RM1131U AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the precaution in the IN section 1833 ...

Page 1835: ... One way Clutch F2 U D Clutch C3 Shift lever position P N R D L 2 C3 Gear position C1 C2 F2 B1 B2 B3 Reverse Parking Neutral 1st 2nd 3rd O D 1st 2nd f 1st f f f f f f f f f f f f f f f f f f f f f f f f f f f Operating F1 f f f f f f AX 2 AUTOMATIC TRANSAXLE U240E AUTOMATIC TRANSAXLE SYSTEM 2005 CELICA RM1131U OPERATION 1834 ...

Page 1836: ...peedometer driven gear from the vehicle speed sensor c Remove the O ring from the vehicle speed sensor 6 INSTALL VEHICLE SPEED SENSOR ASSEMBLY a Coat a new O ring with ATF and install it to the vehicle speed sensor b Install the speedometer driven gear to the vehicle speed sensor with clip c Install the vehicle speed sensor assembly with the bolt Torque 5 5 N m 56 kgf cm 49 in lbf 7 CONNECT VEHICL...

Page 1837: ...new O ring with ATF and install it to the input tur bine speed sensor b Install the input turbine speed sensor with the bolt Torque 11 N m 115 kgf cm 8 ft lbf 7 CONNECT INPUT TURBINE SPEED SENSOR CON NECTOR 8 DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR 9 REMOVE COUNTER GEAR SPEED SENSOR a Remove the bolt and counter gear speed sensor b Remove the O ring from the counter gear speed sensor 10 INS...

Page 1838: ...240E SPEED SENSOR AX 5 2005 CELICA RM1131U 12 INSTALL ECM BRACKET Torque Bolt 18 N m 185 kgf cm 13 ft lbf Nut 12 N m 120 kgf cm 9 ft lbf 13 INSTALL ECM AND ECM CASE Torque 6 9 N m 70 kgf cm 61 in lbf 14 INSTALL BATTERY 1837 ...

Page 1839: ...nd carefully remove the oil pan assem bly Discard the gasket 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the O ring 6 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC TORS 7 REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate and remove the ATF tempera ture sensor 8 SEPARATE WIRE HARNESS FROM 2 CLAMPS 9 CLAMP WIRE HARNESS TO 2 CLAMPS 10 INSTALL ATF TEMPERATURE SENSOR Inst...

Page 1840: ... c Install the oil strainer with the 3 bolts Torque 11 N m 110 kgf cm 8 ft lbf 13 INSTALL OIL PAN Install the oil pan and a new gasket with the 18 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 14 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 15 CONNECT SOLENOID CONNECTOR 16 FILL ATF AND CHECK ATF LEVEL See page DI 669 17 INSTALL LH ENGINE UNDER COVER 1839 ...

Page 1841: ...ION SWITCH a Remove the nut b Remove the nut washer and control shift lever c Using a screwdriver pry off the lock plate d Remove the nut and lock plate e Remove the 2 bolts and pull out the park neutral position switch 4 INSTALL AND ADJUST PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf b Install a new lock plate and nut ...

Page 1842: ...o the control shaft Torque 12 N m 120 kgf cm 9 ft lbf 5 CONNECT PARK NEUTRAL POSITION SWITCH CON NECTOR 6 CHECK PARK NEUTRAL POSITION OPERATION Check that the engine can be started with the shift lever only in the N or P position but not in other position If the engine can not be stated not as started above carry out the adjustment procedure See page DI 669 7 INSTALL AIR CLEANER ASSEMBLY 8 TEST DR...

Page 1843: ...EXAMINE PARTICLES IN OIL PAN Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the trans axle Steel magnetic bearing gear and plate wear Brass non magnetic bushing wear 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the O ring 6 DISCONNECT 5 SHIFT S...

Page 1844: ...EMOVE CHECK BALL BODY AND SPRING 11 REMOVE 3 APPLY GASKETS 12 REMOVE SHIFT SOLENOID VALVE Remove the 5 bolts and 5 shift solenoid valves 13 INSTALL SHIFT SOLENOID VALVE Install the 5 shift solenoid valves with the 5 bolts Torque Bolt A 6 6 N m 67 kgf cm 58 in lbf Bolt B 11 N m 110 kgf cm 8 ft lbf Bolt length Bolt A 12 mm 0 47 in Bolt B 45 mm 1 77 in 14 INSTALL APPLY GASKET a Coat 3 new apply gaske...

Page 1845: ...A 25 mm 0 98 in Bolt B 41 mm 1 61 in Bolt C 45 mm 1 77 in c Check that the manual valve lever contacts the center of the roller at the tip of the detent spring d Tighten the 17 bolts Torque 11 N m 110 kgf cm 8 ft lbf 17 CLAMP WIRE HARNESS TO 2 CLAMPS 18 INSTALL ATF TEMPERATURE SENSOR Install the ATF temperature sensor with the lock plate and bolt Torque 6 6 N m 67 kgf cm 58 in lbf 19 CONNECT 5 SHI...

Page 1846: ...STALL MAGNET IN OIL PAN Install the 3 magnets in the oil pan as shown in the illustration 22 INSTALL OIL PAN Install the oil pan and a new gasket with the 18 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 23 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 24 FILL ATF AND CHECK ATF LEVEL See page DI 669 25 INSTALL LH ENGINE UNDER COVER 1845 ...

Page 1847: ... oil seals SST 09308 10010 4 INSTALL LH SIDE OIL SEAL a Using SST and a hammer drive in a new oil seal SST 09350 32014 09351 32150 09950 70010 09951 07150 Oil seal drive in depth 2 7 0 5 mm 0 106 0 020 in b Coat the oil seal lip with MP grease 5 INSTALL RH SIDE OIL SEAL a Using SST and a hammer drive in a new oil seal SST 09223 00010 Oil seal drive in depth 0 0 5 mm 0 0 020 in b Coat the oil seal ...

Page 1848: ...AX0KL 02 D05909 Stop Light Switch Shift Lock Control Unit Assembly AUTOMATIC TRANSAXLE U240E SHIFT LOCK SYSTEM AX 15 2005 CELICA RM1131U SHIFT LOCK SYSTEM COMPONENTS 1847 ...

Page 1849: ...PECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter measure the voltage at each terminal HINT Do not disconnect the shift lock control unit assembly connec tor Terminal Measuring Condition Voltage V 5 1 IG E Ignition switch ON 10 14 3 1 STP E Depressing brake pedal 10 14 1848 ...

Page 1850: ...Control Name Plate Heater Control Knob Cluster Finish Panel Upper Console Panel Radio Console Box LH End Finish Panel Door Scuff Plate Front Door Opening Trim Front Pillar Garnish Lower Column Cover Headlight Dimmer Switch Lower No 1 Finish Panel Upper Column Cover Wiper and Washer Switch Steering Wheel Spiral Cable Cowl Side Trim w o Power window Console Box Hole Cover w Power window Power Window...

Page 1851: ...on Tube Clamp Clamp O Rings Blower Unit A C Unit Non reusable part No 1 Brace D05925 Key Interlock Cable Transaxle Control Cable Floor Shift Assembly N m kgf cm ft lbf Specified torque 12 120 9 12 120 9 AX 18 AUTOMATIC TRANSAXLE U240E FLOOR SHIFT ASSEMBLY 2005 CELICA RM1131U 1850 ...

Page 1852: ...6 0 63 ø 8 0 32 ø 6 0 24 mm in ø 5 22 0 2055 L 16 0 63 ø 5 0 20 L 18 0 71 ø 5 0 20 L 16 0 63 ø 5 0 20 L 16 0 63 ø 5 0 20 L 14 0 55 ø 4 0 16 L 16 0 63 AUTOMATIC TRANSAXLE U240E FLOOR SHIFT ASSEMBLY AX 19 2005 CELICA RM1131U HINT Screw shapes and sizes are indicated in the table below The codes A N correspond to those indicated on the previous page 1851 ...

Page 1853: ...hift Lock Unit Shaft Control Shift Lever Sub assembly Shift Lever Knob Button Guide Compression Spring Bulb Control Position Indicator Plate Slide Cover Spring Shift Lock Release Button Manual Detent Spring Detent Rod Grooved Pin Spring Shift Lever Knob Sleeve Collar Shift Lever Knob Shift Lever Plate Precoated part AX 20 AUTOMATIC TRANSAXLE U240E FLOOR SHIFT ASSEMBLY 2005 CELICA RM1131U 1852 ...

Page 1854: ...emove the cable end from the rod of the floor shift as sembly b Pull out the cable while pressing the clip of the key inter lock cable c With the key in ACC remove the cable cap claw from the key interlock and pull it d Disconnect the 2 key interlock cable clamps 4 REMOVE FLOOR SHIFT ASSEMBLY a Disconnect the 2 connectors b Disconnect the 2 wire harness clamps from the floor shift assembly c Remov...

Page 1855: ...XLE U240E FLOOR SHIFT ASSEMBLY 2005 CELICA RM1131U d Remove the cable end from the rod of the floor shift as sembly e Pull out the cable while pressing the clip of the transaxle control cable f Remove the floor shift assembly 1854 ...

Page 1856: ...oad to O D main switch wire harness b Remove the O D main switch c Remove the No 2 slide cover d Remove the shift lever stop pin shift lever knob button shift lever knob button guide and compression spring 3 REMOVE UPPER POSITION INDICATOR HOUSING a Remove the upper position indicator housing b Remove the control position indicator plate c Remove the 4 slide covers from the lower position indica t...

Page 1857: ...REMOVE SHIFT LEVER SUB ASSEMBLY Using a screwdriver and hammer drive off the shaft control while disengaging the claw of the shaft control and remove the shift lever sub assembly 8 REMOVE DETENT ROD a Set a 14 mm deep socket wrench b Using a punch and hammer remove the grooved pin c Remove the detent rod and spring d Remove the shift lever knob sleeve from the detent rod 9 REMOVE COLLARS Using a s...

Page 1858: ...pin to the detent rod pin hole A 8 0 0 2 mm 0 315 0 008 in e Check the detent rod operation 3 INSTALL SHIFT LEVER SUB ASSEMBLY a Apply MP grease on the spring b Install the shift lever sub assembly and shaft control to shift lever plate HINT Check that the claw of the shaft control is fit onto the shift lever plate 4 INSTALL MANUAL DETENT SPRING AND SCREW a Apply MP grease to the parts indicated b...

Page 1859: ...or housing as shown in the illustration b Install the control position indicator plate c Install the upper position indicator housing 8 INSTALL SHIFT LEVER KNOB SUB ASSEMBLY a Apply MP grease on the compression spring b Install the compression spring shift lever knob button guide shift lever knob button and shift lever stop pin c Install the No 2 slide cover d Install the O D main switch e Install...

Page 1860: ...ss clamps from the floor shift as sembly e Connect the 2 connector 2 INSTALL KEY INTERLOCK CABLE a Pass the key interlock cable end through the hole in the floor shift assembly HINT Make sure that the claws shown by the arrow in the illustration are locked b With the shift lever in N position set the hole of the cable end to the floor shift assembly to assemble them c At the time of reassembly Wit...

Page 1861: ...t to each position make sure that the shift ing lever moves smoothly can be moderately operated and the position indicator displays correctly Positions which can be operated without pressing the shift lever knob button R N D M D L 2 D N Positions which can be operated only while pressing the shift lever knob button D 2 L N R P Positions which can be operated only while pressing the shift lever kno...

Page 1862: ...of the key can not be locked Readjust the key interlock cable 7 READJUSTMENT OF KEY INTERLOCK CABLE HINT Assembly shall be undertaker in the same way as step 2 a Using a screwdriver unlock the claw of the lock key of the automatic adjustment part b Remove the key interlock cable end from the rod of the floor shift assembly c Pull out the cable while pressing the clip of the key inter lock cable d ...

Page 1863: ...orque Torque Converter Clutch Control Cable Clip z zGasket x6 Oil Cooler Hose zCotter Pin 12 120 9 18 185 13 37 378 28 37 378 28 216 2 200 159 44 450 32 49 500 33 45 459 33 80 816 59 39 398 29 142 1 450 105 157 1 601 116 157 1 601 116 52 530 38 23 230 17 46 470 34 13 130 9 64 650 47 41 418 30 64 650 47 87 890 64 52 530 38 Drain Plug 54 550 40 52 530 38 Test For Line Pressure Plug zGasket 4 9 50 43...

Page 1864: ... GROUND CABLES Torque 18 N m 185 kgf cm 13 ft lbf 8 DISCONNECT CONTROL CABLE FROM CLAMP 9 DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10 DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR 11 REMOVE VEHICLE SPEED SENSOR CONNECTOR 12 REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque 64 N m 650 kgf cm 47 ft lbf 13 DISCONNECT SOLENOID CONNECTOR AND PARK NEUTRAL POSITION SWITCH CONNECT...

Page 1865: ...Remove the 2 bolts and starter Torque 37 N m 378 kgf cm 28 ft lbf 17 REMOVE LH RH CENTER ENGINE UNDER COVERS 18 DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque 54 N m 550 kgf cm 40 ft lbf 19 REMOVE LH AND RH DRIVE SHAFTS See page SA 21 20 DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque 44 N m 450 kgf cm 32 ft lbf 21 REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS SEMBLY HINT Support th...

Page 1866: ... Remove the suspension member 23 REMOVE ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgf cm 64 ft lbf 24 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ERS a Disconnect the 2 PCV hoses b Install the No 1 and No 2 engine hangers in the correct direction Parts No No 1 engine hanger 12281 88600 No 2 engine hanger 12282 88600 Bolt 91512 61020 Torque 38...

Page 1867: ...ACK 28 REMOVE TORQUE CONVERTER CLUTCH MOUNT ING BOLT Turn the crankshaft to gain access and remove the 6 bolts hold ing the crankshaft pulley set bolt with a wrench Torque 41 N m 418 kgf cm 30 ft lbf HINT At the time of installation please refer to the following item First install black colored bolt and then 5 other bolts 29 REMOVE TRANSAXLE ASSEMBLY a Remove the 4 bolts Torque A bolt 46 N m 470 k...

Page 1868: ...lled surface and the front surface of the trans axle housing Correct distance More than 13 3 mm 0 524 in 2 TRANSAXLE INSTALLATION Installation is in the reverse order of removal See page AX 31 HINT S After installation adjust the shift control cable and park neutral position switch See page DI 669 S Fill ATF and check the fluid level See page DI 669 S Perform the test drive of the vehicle S Adjust...

Page 1869: ...othly clockwise If necessary clean the converter and retest the clutch Replace the converter if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR a Set up a dial indicator and measure the drive plate runout b Check the damage of the ring gear Maximum runout 0 20 mm 0 0079 in If the runout is not within the specification or ring gear is dam aged replace the drive pl...

Page 1870: ... AUTOMATIC TRANSAXLE U240E TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX 37 2005 CELICA RM1131U HINT Mark the position of the converter clutch to ensure the installa tion is correctly performed 1869 ...

Page 1871: ...IC TRANSAXLE U341E AUTOMATIC TRANSAXLE SYSTEM AX 1 2005 CELICA RM1131U AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the precautions in the IN section 1870 ...

Page 1872: ...One way Clutch F2 2nd Brake B2 Reverse Brake C3 Shift lever position P N R D L 2 C3 Gear position C1 C2 F2 B1 B2 B3 Reverse Parking Neutral 1st 2nd 3rd O D 1st 2nd 1st f f f f f f f f f f f f f f f f f f f f Operating F1 f f f AX 2 AUTOMATIC TRANSAXLE U341E AUTOMATIC TRANSAXLE SYSTEM 2005 CELICA RM1131U OPERATION 1871 ...

Page 1873: ...peedometer driven gear from the vehicle speed sensor c Remove the O ring from the vehicle speed sensor 6 INSTALL VEHICLE SPEED SENSOR ASSEMBLY a Coat a new O ring with ATF and install it to the vehicle speed sensor b Install the speedometer driven gear to the vehicle speed sensor with clip c Install the vehicle speed sensor assembly with the bolt Torque 5 5 N m 56 kgf cm 49 in lbf 7 CONNECT VEHICL...

Page 1874: ... input turbin speed sensor c Remove the O ring from the input turbin speed sensor 5 INSTALL INPUT TURBIN SPEED SENSOR a Coat a new O ring with ATF and install it to the input turbin speed sensor b Install the input turbin speed sensor with the bolt Torque 5 4 N m 55 kgf cm 48 in lbf c Connect the connector 6 INSTALL ECM BRACKET Torque Bolt 18 N m 185 kgf cm 13 ft lbf Nut 12 N m 120 kgf cm 9 ft lbf...

Page 1875: ...l pan assem bly Discard the gasket 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the O ring 6 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC TORS 7 REMOVE ATF TEMPERATURE SENSOR a Remove the bolt and lock plate and remove the ATF tem perature sensor b Remove the O ring from the ATF temperature sensor 8 INSTALL ATF TEMPERATURE SENSOR a Coat a new O ring with ATF and it to the direc...

Page 1876: ... c Install the oil strainer with the 3 bolts Torque 11 N m 110 kgf cm 8 ft lbf 11 INSTALL OIL PAN Install the oil pan and a new gasket with the 19 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 12 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 13 CONNECT SOLENOID CONNECTOR 14 FILL ATF AND CHECK ATF LEVEL See page DI 758 15 INSTALL LH ENGINE UNDER COVER 1875 ...

Page 1877: ...ION SWITCH a Remove the nut b Remove the nut washer and control shift lever c Using a screwdriver pry off the lock plate d Remove the nut and lock plate e Remove the 2 bolts and pull out the park neutral position switch 4 INSTALL AND ADJUST PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in lbf b Install a new lock plate and nut ...

Page 1878: ...e to the control shaft Torque 12 N m 120 kgf cm 9 ft lbf 5 CONNECT PARK NEUTRAL POSITION SWITCH CON NECTOR 6 CHECK PARK NEUTRAL POSITION OPERATION Check that the engine can be started with the shift lever only in the N or P position but not in other position If the engine can not be stated not as started above carry out the adjustment procedure See page DI 758 7 INSTALL AIR CLEANER ASSEMBLY 8 TEST...

Page 1879: ...scard the gasket 4 EXAMINE PARTICLES IN OIL PAN Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the trans axle Steel magnetic bearing gear and plate wear Brass non magnetic bushing wear 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the O ring 6 D...

Page 1880: ...pring and ac cumulator piston 9 REMOVE CHECK BALL BODY AND SPRING 10 REMOVE 2 APPLY GASKETS 11 REMOVE SHIFT SOLENOID VALVE Remove the 5 bolts and 5 shift solenoid valves 12 INSTALL SHIFT SOLENOID VALVE Install the 5 shift solenoid valves with the 5 bolts Torque Bolt A 6 6 N m 67 kgf cm 58 in lbf Bolt B 11 N m 110 kgf cm 8 ft lbf Bolt length Bolt A 14 mm 0 55 in Bolt B 55 mm 2 17 in 13 INSTALL APPL...

Page 1881: ...6 in Bolt D 22 mm 0 87 in c Temporarily install the detent spring and cover with the 3 bolts Bolt length Bolt B 45 mm 1 77 in Bolt C 32 mm 1 26 in Bolt E 14 mm 0 55 in d Check that the manual valve lever contacts the center of the roller at the tip of the detent spring e Tighten the 15 bolts Torque 11 N m 110 kgf cm 8 ft lbf 16 INSTALL ATF TEMPERATURE SENSOR Install the ATF temperature sensor with...

Page 1882: ...STALL MAGNET IN OIL PAN Install the 2 magnets in the oil pan as shown in the illustration 20 INSTALL OIL PAN Install the oil pan and a new gasket with the 19 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 21 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 22 FILL ATF AND CHECK ATF LEVEL See page DI 758 23 INSTALL LH ENGINE UNDER COVER 1881 ...

Page 1883: ...ge SA 21 3 REMOVE LH AND RH SIDE OIL SEAL Using SST drive out both the side oil seals SST 09308 10010 4 INSTALL LH AND RH SIDE OIL SEAL a Using SST and a hammer drive in a new oil seal SST 09223 00010 Oil seal drive in depth LH side 2 7 0 5 mm 0 106 0 020 in RH side 0 0 5 mm 0 0 020 in b Coat the oil seal lip with MP grease 5 INSTALL LH AND RH DRIVE SHAFTS See page SA 33 6 FILL ATF AND CHECK ATF L...

Page 1884: ...AX0L0 02 D05909 Stop Light Switch Shift Lock Control Unit Assembly AX 14 AUTOMATIC TRANSAXLE U341E SHIFT LOCK SYSTEM 2005 CELICA RM1131U SHIFT LOCK SYSTEM COMPONENTS 1883 ...

Page 1885: ...PECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter measure the voltage at each terminal HINT Do not disconnect the shift lock control unit assembly connec tor Terminal Measuring Condition Voltage V 5 1 IG E Ignition switch ON 10 14 3 1 STP E Depressing brake pedal 10 14 1884 ...

Page 1886: ...Control Name Plate Heater Control Knob Cluster Finish Panel Upper Console Panel Radio Console Box LH End Finish Panel Door Scuff Plate Front Door Opening Trim Front Pillar Garnish Lower Column Cover Headlight Dimmer Switch Lower No 1 Finish Panel Upper Column Cover Wiper and Washer Switch Steering Wheel Spiral Cable Cowl Side Trim w o Power window Console Box Hole Cover w Power window Power Window...

Page 1887: ...on Tube Clamp Clamp O Rings Blower Unit A C Unit Non reusable part No 1 Brace D05925 Key Interlock Cable Transaxle Control Cable Floor Shift Assembly N m kgf cm ft lbf Specified torque 12 120 9 12 120 9 AUTOMATIC TRANSAXLE U341E FLOOR SHIFT ASSEMBLY AX 17 2005 CELICA RM1131U 1886 ...

Page 1888: ...6 0 63 ø 8 0 32 ø 6 0 24 mm in ø 5 22 0 2055 L 16 0 63 ø 5 0 20 L 18 0 71 ø 5 0 20 L 16 0 63 ø 5 0 20 L 16 0 63 ø 5 0 20 L 14 0 55 ø 4 0 16 L 16 0 63 AX 18 AUTOMATIC TRANSAXLE U341E FLOOR SHIFT ASSEMBLY 2005 CELICA RM1131U HINT Screw shapes and sizes are indicated in the table below The codes A N correspond to those indicated on the previous page 1887 ...

Page 1889: ... Unit Shaft Control Shift Lever Sub assembly Shift Lever Knob Button Guide Compression Spring Bulb Control Position Indicator Plate Slide Cover Spring Shift Lock Release Button Manual Detent Spring Detent Rod Shift Lever Knob Sleeve Collar Shift Lever Knob Shift Lever Plate Precoated part Spring Bulb Cap Grooved Pin AUTOMATIC TRANSAXLE U341E FLOOR SHIFT ASSEMBLY AX 19 2005 CELICA RM1131U 1888 ...

Page 1890: ...emove the cable end from the rod of the floor shift as sembly b Pull out the cable while pressing the clip of the key inter lock cable c With the key in ACC remove the cable cap claw from the key interlock and pull it d Disconnect the 2 key interlock cable clamps 4 REMOVE FLOOR SHIFT ASSEMBLY a Disconnect the 2 connectors b Disconnect the 2 wire harness clamps from the floor shift assembly c Remov...

Page 1891: ...41E FLOOR SHIFT ASSEMBLY AX 21 2005 CELICA RM1131U d Remove the cable end from the rod of the floor shift as sembly e Pull out the cable while pressing the clip of the transaxle control cable f Remove the floor shift assembly 1890 ...

Page 1892: ...tion not to apply unnatural load to O D main switch wire harness b Remove the O D main switch c Remove the No 2 slide cover d Remove the shift lever stop pin shift lever knob button shift lever knob button guide and compression spring 3 REMOVE UPPER POSITION INDICATOR HOUSING a Remove the upper position indicator housing b Remove the control position indicator plate c Remove the 3 slide covers fro...

Page 1893: ...REMOVE SHIFT LEVER SUB ASSEMBLY Using a screwdriver and hammer drive off the shaft control while disengaging the claw of the shaft control and remove the shift lever sub assembly 8 REMOVE DETENT ROD a Set a 14 mm deep socket wrench b Using a punch and hammer remove the grooved pin c Remove the detent rod and spring d Remove the shift lever knob sleeve from the detent rod 9 REMOVE COLLARS Using a s...

Page 1894: ...h and hammer install the grooved pin to the detent rod pin hole A 8 0 0 2 mm 0 315 0 008 in e Check the detent rod operation 3 INSTALL SHIFT LEVER SUB ASSEMBLY a Apply MP grease on the spring b Install the shift lever sub assembly and shaft control to shift lever plate HINT Check that the claw of the shaft control is fit onto the shift lever plate 4 INSTALL MANUAL DETENT SPRING AND SCREW a Apply M...

Page 1895: ...assembly 7 INSTALL UPPER POSITION INDICATOR HOUSING a Install the 3 slide covers to the lower position indicator housing as shown in the illustration b Install the control position indicator plate c Install the upper position indicator housing 8 INSTALL SHIFT LEVER KNOB SUB ASSEMBLY a Apply MP grease on the compression spring b Install the compression spring shift lever knob button guide shift lev...

Page 1896: ...HIFT ASSEMBLY 2005 CELICA RM1131U NOTICE Make sure not to catch O D main switch wire harness 9 INSTALL O D MAIN SWITCH TERMINAL a Connect the 2 O D main switch terminals to the connec tor b Connect the connector to the shift lever plate 1895 ...

Page 1897: ...lamps from the floor shift as sembly e Connect the 2 connectors 2 INSTALL KEY INTERLOCK CABLE a Pass the key interlock cable end through the hole in the floor shift assembly HINT Make sure that the claws shown by the arrow in the illustration are locked b With the shift lever in N position set the hole of the cable end to the floor shift assembly to assemble them c At the time of reassembly With t...

Page 1898: ...it to each position make sure that the shift ing lever moves smoothly can be moderately operated and the position indicator displays correctly Positions which can be operated without pressing the shift lever knob button R N D D L 2 D N Positions which can be operated only while pressing the shift lever knob button D 2 L N R P Positions which can be operated only while pressing the shift lever knob...

Page 1899: ... the key can not be locked Readjust the key interlock cable 7 READJUSTMENT OF KEY INTERLOCK CABLE HINT Assembly shall be undertaker in the same way as step 2 a Using a screwdriver unlock the claw of the lock key of the automatic adjustment part b Remove the key interlock cable end from the rod of the floor shift assembly c Pull out the cable while pressing the clip of the key inter lock cable d Re...

Page 1900: ... Torque Converter Clutch Control Cable Clip z zGasket x6 Oil Cooler Hose zCotter Pin 12 120 9 37 378 28 37 378 28 216 2 200 159 44 450 32 49 500 33 80 816 59 39 398 29 142 1 450 105 157 1 601 116 157 1 601 116 52 530 38 13 130 9 64 650 47 41 420 25 64 650 47 87 890 64 52 530 38 52 530 38 Drain Plug 54 550 40 18 185 13 46 470 34 23 230 17 7 0 71 62 in lbf 4 9 50 43 in lbf 6 9 70 61 in lbf 6 9 70 61...

Page 1901: ...f cm 62 in lbf 7 REMOVE 2 GROUND CABLES Torque 18 N m 185 kgf cm 13 ft lbf 8 DISCONNECT CONTROL CABLE FROM CLAMP 9 DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10 REMOVE VEHICLE SPEED SENSOR CONNECTOR 11 REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque 64 N m 650 kgf cm 47 ft lbf 12 DISCONNECT SOLENOID CONNECTOR AND PARK NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoi...

Page 1902: ...Remove the 2 bolts and starter Torque 37 N m 378 kgf cm 28 ft lbf 16 REMOVE LH RH CENTER ENGINE UNDER COVERS 17 DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque 54 N m 550 kgf cm 40 ft lbf 18 REMOVE LH AND RH DRIVE SHAFTS See page SA 21 19 DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque 44 N m 450 kgf cm 32 ft lbf 20 REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS SEMBLY HINT Support th...

Page 1903: ...the suspension member 22 REMOVE ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgf cm 64 ft lbf 23 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ERS a Disconnect the 2 PCV hoses b Install the No 1 and No 2 engine hangers in the correct direction Parts No No 1 engine hanger 12281 22021 No 2 engine hanger 12281 15040 or 12281 15050 Bolt 91512 B1016 To...

Page 1904: ...E TORQUE CONVERTER CLUTCH MOUNT ING BOLT a Remove the hole plug b Turn the crankshaft to gain access and remove the 6 bolts holding the crankshaft pulley set bolt with a wrench Torque 41 N m 420 kgf cm 30 ft lbf HINT At the time of installation please refer to the following item First install black colored bolt and then 5 other bolts 28 REMOVE TRANSAXLE ASSEMBLY a Remove the 4 bolts Torque A bolt ...

Page 1905: ...lled surface and the front surface of the trans axle housing Correct distance More than 13 3 mm 0 524 in 2 TRANSAXLE INSTALLATION Installation is in the reverse order of removal See page AX 31 HINT S After installation adjust the shift control cable and park neutral position switch See page DI 758 S Fill ATF and check the fluid level See page DI 758 S Perform the test drive of the vehicle S Adjust...

Page 1906: ...y clockwise If necessary clean the converter and retest the clutch Replace the converter clutch if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR a Set up a dial indicator and measure the drive plate runout b Check the damage of the ring gear Maximum runout 0 20 mm 0 0079 in If the runout is not within the specification or ring gear is dam aged replace the drive...

Page 1907: ... AUTOMATIC TRANSAXLE U341E TORQUE CONVERTER CLUTCH AND DRIVE PLATE AX 37 2005 CELICA RM1131U HINT Mark the position of the converter clutch to ensure the installa tion is correctly performed 1906 ...

Page 1908: ...rn SA 34 SA 62 SA 37 SA 65 Sways pitches 1 Tire Worn or improperly inflated 2 Stabilizer bar Bent or broken 3 Shock absorber Worn SA 3 SA 51 SA 76 SA 37 SA 65 Front wheel shimmy 1 Tire Worn or improperly inflated 2 Wheel Out of balance 3 Shock absorber Worn 4 Wheel alignment Incorrect 5 Ball joint Worn 6 Hub bearing Worn 7 Steering linkage Loose or worn 8 Steering gear Out of adjustment or broken ...

Page 1909: ...ng off center Adjust front tie rods NO YES Is the lead pull stronger than before YES NOTICE Do not exceed 1 of cross camber Do not exceed adjustment range Select a flat road where the vehicle can be driven in a straight line for 100 meters at a constant speed of 35mph Please confirm safety and set the steering wheel to its straight position Drive the vehicle in a straight line for 100 meters at a ...

Page 1910: ...2 psi 195 60R15 88H P195 60R15 87H 210 2 1 29 210 2 1 29 2ZZ GE engine models Tire size Front kPa kgf cm2 psi Rear kPa kgf cm2 psi 205 55R15 87V P205 55R15 87V 205 50R16 87V 220 2 2 32 220 2 2 32 b Using a dial indicator check the tire runout Tire runout 1 0 mm 0 039 in or less 2 ROTATING TIRES HINT S Rotate tires as shown in the illustration S Rotate as shown in B if the spare tire is included in...

Page 1911: ...ear the center of the axle hub Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the bearing b Using a dial indicator check the deviation at the surface of the axle hub outside the hub bolt Maximum 0 07 mm 0 0028 in If the deviation exceeds the maximum replace the axle hub 5 CHECK FRONT SUSPENSION FOR LOOSENESS 6 CHECK STEERING LINKAGE FOR LOOSENESS 7 CHECK BALL JOINT FOR LOOSE...

Page 1912: ...r of the rear side lower suspension arm suspension member side set bolt NOTICE Before inspecting the wheel alignment adjust the vehicle height to the specified value If the vehicle height is not the specified value try to adjust it by pushing down on or lifting the body 2 INSTALL CAMBER CASTER KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES TER Follow the specific instructions of the equi...

Page 1913: ...ter Right left error 2 02 45 2 03 0 75 45 0 75 or less Steering axis inclination Right left error 13 12 45 13 20 0 75 45 0 75 or less If the caster and steering axis inclination are not within the spe cified values after the camber has been correctly adjusted re check the suspension parts for damaged and or worn out parts 4 ADJUST CAMBER NOTICE After the camber has been adjusted inspect the toe in...

Page 1914: ...N m 1 050 kgf cm 76 ft lbf h Check the camber HINT S Try to adjust the camber to the center of the specified val ue S Adjusting value for the set bolts is 6 30 0 1 0 5 If the camber is not within the specified value using the follow ing table estimate how much additional camber adjustment will be required and select the camber adjusting bolt i Do the steps mentioned above again Between step b and ...

Page 1915: ...ie rod end lock nuts Torque 74 N m 750 kgf cm 54 ft lbf f Place the boots on the seats and install the clips HINT Make sure that the boots are not twisted 7 INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle Wheel turning angle 195 60R15 P195 60R15 tire Inside wheel 38 41 2 38 68 2 Outside wheel Reference 33 20 33 33 205 55R15 P205 55R15 tire Inside wheel 38 46 2 38 77...

Page 1916: ... Toe in total A B 0 18 12 0 3 0 2 C D 3 2 mm 0 12 0 08 in If the toe in is not within the specified value see step 5 to ad just 5 ADJUST CAMBER AND TOE IN a Measure the distance from the LH lower suspension arm bracket set bolt to the RH axle carrier rear side set bolt as shown in the illustration b Employ the same manner to the RH LH Length difference 6 mm or less If it exceeds the specified valu...

Page 1917: ...d value A and the measured value B on the adjustment chart Standard value Camber 1 11 1 18 Toe in total IN 3mm 0 12 in Formula A B C Camber RH 1 11 0 26 0 45 Camber LH 1 11 1 56 0 45 Toe in total IN3 IN7 OUT 4 Toe in each side OUT 2 c As shown in the example chart read the distance from the marked point to the origin of the chart and adjust the up per and or lower arm adjusting cams accordingly Am...

Page 1918: ...F08653 Camber Toe in Outward Upper arm cam graduation Outward Inward Lower arm cam graduation Inward SUSPENSION AND AXLE REAR WHEEL ALIGNMENT SA 11 2005 CELICA RM1131U 1917 ...

Page 1919: ...with Axle Hub Disc Brake Caliper Lower Suspension Arm 142 1 450 105 z Lock Nut 216 2 200 159 z Snap Ring z Cotter Pin z Bearing Steering Knuckle 103 1 050 76 Lower Ball Joint Dust Cover 8 3 85 74 in lbf Axle Hub N m kgf cm ft lbf Specified torque z Non reusable part w ABS SA 12 SUSPENSION AND AXLE FRONT AXLE HUB 2005 CELICA RM1131U FRONT AXLE HUB COMPONENTS 1918 ...

Page 1920: ...ds the maximum replace the bearing d Using a dial indicator check the deviation at the surface of the axle hub outside the hub bolt Maximum 0 07 mm 0 0028 in If the deviation exceeds the maximum replace the axle hub e Install the disc 2 bolts and brake caliper Torque 107 N m 1 090 kgf cm 79 ft lbf 3 REMOVE DRIVE SHAFT LOCK NUT a Using SST and a hammer unstake the staked part of the lock nut SST 09...

Page 1921: ... for a new cotter pin are not aligned tighten the nut further up to 60 b Using SST disconnect the tie rod end from the steering knuckle SST 09610 20012 7 DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt Torque 142 N m 1 450 kgf cm 105 ft lbf 8 REMOVE STEERING KNUCKLE WITH AXLE HUB a Remove the 2 bolts and nuts on the lower side of the shock absorber HINT At the time...

Page 1922: ...00031 09520 00040 09521 00010 09521 00020 b Using SST and a press remove the inner race outside from the axle hub SST 09555 55010 09950 60010 09951 00380 09950 70010 09951 07150 3 REMOVE DUST COVER Using a torx socket T30 remove the 3 bolts and dust cover 4 REMOVE BEARING FROM STEERING KNUCKLE a Using snap ring pliers remove the snap ring b Place the inner race on the outside of the bearing c Usin...

Page 1923: ... ring 2 INSTALL DUST COVER Place the dust cover and using a torx socket T30 install the 3 bolts Torque 8 3 N m 85 kgf cm 74 in lbf 3 INSTALL FRONT AXLE HUB Using SST and a press install the axle hub SST 09608 32010 09950 60010 09951 00550 09950 70010 09951 07150 4 INSTALL LOWER BALL JOINT a Install the lower ball joint and tighten the nut Torque 103 N m 1 050 kgf cm 76 ft lbf b Install a new cotte...

Page 1924: ...ONT AXLE HUB SA 17 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 13 HINT After installation check the ABS speed sensor signal See page DI 836 and front wheel alignment See page SA 5 1923 ...

Page 1925: ... HUB BOLT Using SST 2 nuts and a screwdriver or an equivalent remove the hub bolt SST 09628 10011 4 INSTALL HUB BOLT a Install a washer and nut to a new hub bolt as shown in the illustration b Using a screwdriver or an equivalent to hold install the hub bolt by torquing the nut c Remove the 3 nuts and washer 5 INSTALL DISC AND BRAKE CALIPER Install the disc brake caliper and 2 bolts Torque 107 N m...

Page 1926: ...200 159 49 500 36 142 1 450 105 Drive Shaft LH z Snap Ring Outboard Joint Shaft z Dust Cover Inboard Joint Shaft z Clamp z Boot Steering Knuckle with Axle Hub z Clamp z Boot z Snap Ring z Center Bearing Center Bearing Case Straight Pin Cage z Snap Ring Inner Race Ball z Snap Ring RH Center Bearing Bracket 64 650 47 M T Dynamic Damper z Clamp SUSPENSION AND AXLE FRONT DRIVE SHAFT SA 19 2005 CELICA ...

Page 1927: ...teering Knuckle with Axle Hub Drive Shaft RH Drive Shaft LH z Snap Ring Center Bearing Bracket 64 650 47 Outboard Joint Shaft z Clamp z Boot LH z Dust Cover Inboard Joint Shaft z Clamp z Boot z Dust Cover Inboard Joint Shaft z Snap Ring z Center Bearing Center Bearing Case Straight Pin RH z Snap Ring Tripod SA 20 SUSPENSION AND AXLE FRONT DRIVE SHAFT 2005 CELICA RM1131U 1926 ...

Page 1928: ...s not to damage the ABS speed sensor rotor serrations on the drive shaft 1 REMOVE FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 2 REMOVE ENGINE UNDER COVER 3 DRAIN GEAR OIL M T OR ATF A T 4 REMOVE DRIVE SHAFT LOCK NUT a Using SST and a hammer unstake the staked part of the lock nut SST 09930 00010 b While applying the brakes remove the nut Torque 216 N m 2 200 kgf cm 159 ft lbf 5 DISCONNECT TI...

Page 1929: ...o damage the oil seal and dust cover 9 LH drive shaft REMOVE DRIVE SHAFT a Using SST remove the drive shaft SST 09520 01010 09520 24010 09520 32040 NOTICE Be careful not to damage the oil seal and dust cover HINT At the time of installation please refer to the following items S Apply gear oil to the inboard joint shaft and differential case sliding surfaces S Before installing the drive shaft set ...

Page 1930: ...he inboard joint 4 Check the boots for damage b Remove the inboard and outboard joint boot clamps 1 Using a screwdriver disclamp the 2 inboard joint boot clamps 2 Using a side cutter cut the 2 outboard joint boot clamps and remove them c M T Remove the dynamic damper clamp Using a screwdriver disclamp the dynamic damper clamp d Remove the inboard joint shaft 1 Slide the inboard joint boot toward t...

Page 1931: ...ard and outboard joint boots and inboard joint clamps NOTICE Do not disassemble the outboard joint 2 1ZZ FE engine A T DISASSEMBLE DRIVE SHAFT a Check the drive shaft 1 Check to see that there is no remarkable play in the outboard joint 2 Check to see that the inboard joint slides smoothly in the thrust direction 3 Check to see that there is no remarkable play in the radial direction of the inboar...

Page 1932: ...nt shaft and tripod NOTICE Do not punch the marks 3 Using a brass bar and hammer remove the tripod from the outboard joint shaft NOTICE Do not tap the roller e Remove the inboard and outboard joint boots and in board joint clamps NOTICE Do not disassemble the out board joint 3 DISASSEMBLE INBOARD JOINT SHAFT a LH Remove the dust cover Using SST and a press remove the dust cover SST 09950 00020 b L...

Page 1933: ...ewdriver remove the outside snap ring 2 Using a press remove the center bearing case 3 Using a pin punch and hammer remove the straight pin from the center bearing case 4 Using SST and a press remove the dust cover SST 09950 00020 5 Using a snap ring expander remove the inside snap ring 6 Using a press remove the center bearing 1932 ...

Page 1934: ...he straight pin into the center bearing case 2 Using SST and a press install a new center bearing into the bearing case SST 09950 60010 09951 00650 09950 70010 09951 07150 3 Using a screwdriver install a new outside snap ring 4 Using SST and a press install the center bearing with the bearing case assembly to the inboard joint shaft SST 09710 30021 09710 03141 5 Using a snap ring expander install ...

Page 1935: ... Place 2 new clamps on a new inboard joint boot and install them to the outboard joint shaft b Install the tripod 1 Place the beveled side of the tripod axial spline to ward the outboard joint 2 Align the matchmarks placed before removal 3 Using a brass bar and hammer tap in the tripod to the outboard joint shaft NOTICE Do not tap the roller 4 Using a snap ring expander install a new snap ring c I...

Page 1936: ...ten the SST so that the large clamp is pinched NOTICE Do not overtighten the SST 7 Using SST adjust the clearance of the large clamp SST 09240 00020 Clearance 0 8 mm 0 031 in or less 8 Employ the same manner to the outboard joint small boot clamp 3 1ZZ FE engine M T and 2ZZ GE engine REASSEMBLE DRIVE SHAFT a Temporarily install dynamic damper M T new outboard and inboard joint boots and new clamps...

Page 1937: ... to damage the inner race 4 Using a snap ring expander install a new snap ring 5 Align the matchmarks on the cage and inner race 6 Install the cage to the inner race 7 Install the 6 balls HINT Apply grease onto the balls to keep them from falling c Install the boot to outboard joint Before assembling the boot pack the outboard joint and boot with grease in the boot kit Grease capacity Color Black ...

Page 1938: ...sure that the boots are not stretched or con tracted when the drive shaft is at standard length Drive shaft standard length RH 845 5 5 0 mm 33 287 0 197 in LH 563 7 5 0 mm 22 193 0 197 in 3 Bend the band and lock the inboard joint boot clamps with a screwdriver 4 Secure the 2 outboard joint boot clamps onto the boot 5 Place SST onto the outboard joint large boot clamp SST 09521 24010 6 Tighten the...

Page 1939: ...5 CELICA RM1131U f M T Assemble the dynamic damper clamp 1 Set the dynamic damper distance as described be low Distance 155 0 2 0 mm 6 102 0 079 in 2 Bend the band and lock the dynamic damper clamp with a screwdriver 4 CHECK DRIVE SHAFT See page SA 23 1938 ...

Page 1940: ...ONT DRIVE SHAFT SA 33 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order removal See page SA 21 HINT After installation check the ABS speed sensor signal See page DI 836 and front wheel alignment See page SA 5 1939 ...

Page 1941: ...4 449 32 153 1 560 113 Cap z 47 475 34 Suspension Support Dust Seal Spring Seat Upper Insulator Coil Spring Spring Bumper Lower Insulator Shock Absorber N m kgf cm ft lbf Specified torque z Non reusable part Stabilizer Bar Link SA 34 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 2005 CELICA RM1131U FRONT SHOCK ABSORBER COMPONENTS 1940 ...

Page 1942: ...ONNECT STABILIZER BAR LINK Remove the nut and disconnect the stabilizer bar link from the shock absorber Torque 44 N m 449 kgf cm 32 ft lbf HINT If the ball joint turns together with the nut use a hexagon 5 mm wrench to hold the stud 5 REMOVE SHOCK ABSORBER WITH COIL SPRING a Loosen the 2 nuts on the lower side of shock absorber Torque 153 N m 1 560 kgf cm 113 ft lbf HINT Do not remove the 2 bolts...

Page 1943: ...rber and secure it in a vise b Using SST compress the coil spring SST 09727 30021 09727 00010 09727 00021 09727 00031 NOTICE Do not use an impact wrench It will damage the SST c Remove the cap from the suspension support d Using SST to hold the spring seat remove the nut SST 09729 22031 e Remove the suspension support dust seal spring seat upper insulator coil spring spring bumper and lower insu l...

Page 1944: ...TION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during opera tion If there is any abnormality replace the shock absorber with a new one NOTICE When disposing of the shock absorber see DISPOSAL on page SA 38 1943 ...

Page 1945: ...L 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill make a hole in the cylinder as shown in the illustra tion to discharge the gas inside CAUTION S When drilling chips may fly out work carefully S The gas is colorless odorless and non poisonous 1944 ...

Page 1946: ...an impact wrench It will damage the SST b Install the coil spring to the shock absorber HINT Fit the lower end of the coil spring into the gap of the spring low er seat c Install the upper insulator as shown in the illustration d Install the spring seat to the shock absorber with the mark facing to the outside of the vehicle e Install the dust seal and suspension support f Using SST to hold the su...

Page 1947: ...F07341 MP Grease SA 40 SUSPENSION AND AXLE FRONT SHOCK ABSORBER 2005 CELICA RM1131U h Apply MP grease into the suspension support i Install the cap 1946 ...

Page 1948: ...PENSION AND AXLE FRONT SHOCK ABSORBER SA 41 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 35 HINT After installation check the front wheel alignment See page SA 5 1947 ...

Page 1949: ... Cotter Pin Lower Suspension Arm 49 500 36 58 591 43 13 130 9 157 1 600 116 157 1 600 116 44 449 32 137 1 397 101 52 530 38 142 1 450 105 142 1 450 105 52 530 38 52 530 38 39 400 29 137 1 397 101 44 449 32 SA 42 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 2005 CELICA RM1131U FRONT LOWER SUSPENSION ARM COMPONENTS 1948 ...

Page 1950: ... 2 bolts nut and lower suspension arm Torque 137 N m 1 397 kgf cm 101 ft lbf HINT At the time of installation after stabilizing the suspension torque the bolts 3 A T LH side REMOVE LOWER SUSPENSION ARM a Remove the engine under covers b Disconnect the RH and LH tie rod ends 1 Remove the cotter pin and nut Torque 49 N m 500 kgf cm 36 ft lbf HINT At the time of installation if the holes for a new co...

Page 1951: ...5 ft lbf 2 Employ the same manner described above to the other side e Loosen the lower suspension arm set bolts Torque 137 N m 1 397 kgf cm 101 ft lbf HINT At the time of installation after stabilizing the suspension torque the bolts f Remove the engine hood See page BO 9 g Attach the engine sling device to the engine hangers 1 Disconnect the 2 PCV hoses 2 Install the No 1 and No 2 engine hangers ...

Page 1952: ...it securely i Remove the bolt A and 3 nuts and disconnect the engine rear mount Torque 52 N m 530 kgf cm 38 ft lbf j Remove the 2 bolts B and disconnect the engine front mount Torque 52 N m 530 kgf cm 38 ft lbf k Using a transmission jack support the suspension mem ber l Remove the 6 bolts C and D and lower the suspension member Torque Bolt C 157 N m 1 600 kgf cm 116 ft lbf Bolt D 39 N m 400 kgf c...

Page 1953: ...SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 43 HINT After installation check the front wheel alignment See page SA 5 1952 ...

Page 1954: ... Axle Hub Lower Ball Joint Lower Suspension Arm Tie Rod End Disc z Lock Nut ABS Speed Sensor z Cotter Pin z Cotter Pin Brake Caliper 80 82 71 in lbf 153 1 560 113 107 1 090 79 142 1 450 105 49 500 36 103 1 050 76 SUSPENSION AND AXLE FRONT LOWER BALL JOINT SA 47 2005 CELICA RM1131U FRONT LOWER BALL JOINT COMPONENTS 1953 ...

Page 1955: ...ON AND AXLE FRONT LOWER BALL JOINT 2005 CELICA RM1131U REMOVAL 1 REMOVE STEERING KNUCKLE WITH AXLE HUB See page SA 13 2 REMOVE LOWER BALL JOINT a Remove the cotter pin and nut b Using SST remove the lower ball joint SST 09628 62011 1954 ...

Page 1956: ...NT FOR ROTATION CONDI TION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 1 0 4 9 N m 10 50 kgf cm 8 7 43 in lbf 1955 ...

Page 1957: ...e lower ball joint and tighten the nut Torque 103 N m 1 050 kgf cm 76 ft lbf b Install a new cotter pin If the holes for the cotter pin are not aligned tighten the nut fur ther up to 60 2 INSTALL STEERING KNUCKLE WITH AXLE HUB See page SA 17 3 CHECK ABS SPEED SENSOR SIGNAL See page DI 836 4 CHECK FRONT WHEEL ALIGNMENT See page SA 5 1956 ...

Page 1958: ...t PS Gear Assembly Stabilizer Bar Link Bracket Bushing Stabilizer Bar 39 400 29 52 530 38 52 530 38 142 1 450 105 157 1 600 116 44 449 32 52 530 38 142 1 450 105 44 449 32 19 194 14 58 591 43 49 500 36 13 130 9 SUSPENSION AND AXLE FRONT STABILIZER BAR SA 51 2005 CELICA RM1131U FRONT STABILIZER BAR COMPONENTS 1957 ...

Page 1959: ...oy the same manner described above to the other side 2 REMOVE FRONT SUSPENSION MEMBER WITH LOW ER SUSPENSION ARM See page SA 43 3 REMOVE STABILIZER BAR a Remove the 2 bolts bracket and bushing Torque 19 N m 194 kgf cm 14 ft lbf HINT At the time of installation please refer to the following items S Install the bushing so that the cutout will face to the rear S Install the bushing to the outside of ...

Page 1960: ... JOINT FOR ROTA TION CONDITION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 in lbf 1959 ...

Page 1961: ...54 SUSPENSION AND AXLE FRONT STABILIZER BAR 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 52 HINT After installation check the front wheel alignment See page SA 5 1960 ...

Page 1962: ...ub Cam Plate Hub Bolt Upper Suspension Arm ABS Speed Sensor Connector 47 475 34 Drum brake Hub Bolt Drum Disc Cam Bolt Axle Hub Assembly Rear Axle Carrier Stabilizer Bar z ABS Speed Sensor w ABS 74 755 55 Axle Hub Assembly 44 449 32 56 571 41 74 755 55 SUSPENSION AND AXLE REAR AXLE CARRIER SA 55 2005 CELICA RM1131U REAR AXLE CARRIER COMPONENTS 1961 ...

Page 1963: ...r of the axle hub Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the axle hub b Using a dial indicator check the deviation at the surface of the axle hub outside the hub bolt Maximum 0 07 mm 0 0028 in If the deviation exceeds the maximum replace the axle hub 5 w ABS DISCONNECT ABS SPEED SENSOR CONNECTOR 6 REMOVE REAR AXLE HUB a Remove the 4 bolts and axle hub assembly Torque...

Page 1964: ...g the suspension torque the bolt 9 REMOVE REAR AXLE CARRIER a Remove the front side bolt and nut of the lower suspen sion arm Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut b Place matchmarks on both the cam plate and lower sus pension arm c Remove the nut cam plate and cam bolt Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time...

Page 1965: ...e NOTICE Replace the axle hub assembly if it is dropped or a strong shock is given to it c Using SST and 2 bolts Diameter 12 mm Pitch 1 5 mm remove the ABS speed sensor SST 09520 00031 09520 00040 09521 00020 09950 00020 NOTICE S Do not allow any foreign matter sticking to the sensor rotor S Pull out the ABS speed sensor straightly not to dam age the sensor rotor S If damage has occurred to the se...

Page 1966: ...er sticking to the sensor rotor b Place the ABS speed sensor on the axle hub so that the connector is set at the bottom under the on vehicle condi tion c Using SST and a press install a new ABS speed sensor to the axle hub SST 09214 76011 NOTICE S Do not tap the speed sensor with a hammer directly S Check that there should be no foreign matter on the speed sensor detection portion S Press in the A...

Page 1967: ...LE REAR AXLE CARRIER 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 56 HINT After installation check the ABS speed sensor signal See page DI 836 and rear wheel alignment See page SA 9 1966 ...

Page 1968: ...rum brake REMOVE BRAKE DRUM 4 REMOVE HUB BOLT Using SST and a brass bar remove the hub bolt SST 09628 10011 5 INSTALL HUB BOLT a Install a washer and nut to a new hub bolt as shown in the illustration b Using a brass bar to hold install the hub bolt by torquing the nut 6 w Drum brake INSTALL BRAKE DRUM 7 w Disc brake INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper and 2 bolts Tor...

Page 1969: ... 80 816 59 43 440 32 Parking Brake Cable Lower Suspension Arm Cam Plate 74 755 55 65 663 48 74 755 55 Cam Bolt 74 755 55 Spring Bumper Cushion Spring Bracket Upper Insulator Coil Spring 56 571 41 Shock Absorber Shock Absorber with Coil Spring Suspension Support 19 194 14 5 4 55 48 in lbf Rear Deck Trim Cover SA 62 SUSPENSION AND AXLE REAR SHOCK ABSORBER 2005 CELICA RM1131U REAR SHOCK ABSORBER COMP...

Page 1970: ...que 103 N m 1 050 kgf cm 76 ft lbf 2 REMOVE PACKAGE TRAY TRIM 3 REMOVE LUGGAGE COMPARTMENT MAT 4 REMOVE REAR DECK TRIM COVER 5 REMOVE DECK TRIM SIDE PANEL 6 REMOVE REAR LOWER SUSPENSION ARM See page SA 73 7 REMOVE REAR SHOCK ABSORBER Remove the 3 nuts and rear shock absorber Torque 80 N m 816 kgf cm 59 ft lbf 1969 ...

Page 1971: ...Using SST compress the coil spring SST 09727 30021 09727 00010 09727 00021 09727 00031 NOTICE Do not use an impact wrench It will damage the SST b Using a 6 mm hexagon wrench to hold the piston rod re move the nut c Remove the washer cushion spring bracket upper insu lator suspension support spring bumper and coil spring 1970 ...

Page 1972: ... INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual sound during opera tion If there is any abnormality replace the shock absorber with a new one NOTICE When disposing of the shock absorber see DISPOSAL on page SA 66 1971 ...

Page 1973: ...L 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill make a hole in the cylinder as shown in the illustra tion to discharge the gas inside CAUTION S When drilling chips may fly out work carefully S The gas is colorless odorless and non poisonous 1972 ...

Page 1974: ...he lower end of the coil spring into the gap of the spring low er seat 2 INSTALL SPRING BUMPER AND SUSPENSION SUP PORT 3 INSTALL SPRING BRACKET a Set the upper insulator to the spring bracket b Position the spring bracket with upper insulator as shown in the illustration c Install the cushion and washer d Temporarily tighten the center nut e Remove the SST SST 09727 30021 09727 00010 09727 00021 0...

Page 1975: ... 68 SUSPENSION AND AXLE REAR SHOCK ABSORBER 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 63 HINT After installation check the rear wheel alignment See page SA 9 1974 ...

Page 1976: ...fied torque z Gasket Heat Insulator Cam Plate Upper Suspension Arm Tailpipe Spring O Ring Suspension Member Cam Bolt 74 755 55 43 440 32 74 755 55 SUSPENSION AND AXLE REAR UPPER SUSPENSION ARM SA 69 2005 CELICA RM1131U REAR UPPER SUSPENSION ARM COMPONENTS 1975 ...

Page 1977: ...ft lbf b Remove the 4 bolts and heat insulator 3 REMOVE UPPER SUSPENSION ARM a Place matchmarks on both the cam plate and suspension member b Remove the nut cam plate and cam bolt Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut c Remove the bolt nut and upper suspension arm Torque 74 N m 755 kgf cm 55 ft lbf NOTICE Do not turn the...

Page 1978: ...NSION AND AXLE REAR UPPER SUSPENSION ARM SA 71 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 70 HINT After installation check the rear wheel alignment See page SA 9 1977 ...

Page 1979: ... Arm 74 755 55 Parking Brake Cable ABS Speed Sensor Wire Harness 5 4 55 48 in lbf 5 4 55 48 in lbf Cam Plate 74 755 55 19 194 14 140 1 428 103 Cam Bolt 74 755 55 110 1 122 81 Suspension Arm Bracket Stopper z 65 663 48 SA 72 SUSPENSION AND AXLE REAR LOWER SUSPENSION ARM 2005 CELICA RM1131U REAR LOWER SUSPENSION ARM COMPONENTS 1978 ...

Page 1980: ...t lbf 4 DISCONNECT PARKING BRAKE CABLE CLAMP Remove the 2 bolts and disconnect the parking brake cable clamps Torque 5 4 N m 55 kgf cm 48 in lbf 5 LOOSEN 3 BOLTS ON FRONT SIDE OF LOWER SUS PENSION ARM Torque 65 N m 663 kgf cm 48 ft lbf HINT S Do not remove the bolts S At the time of installation after stabilizing the suspension torque the bolts 6 DISCONNECT REAR AXLE CARRIER FROM LOWER SUSPENSION ...

Page 1981: ... m 1 428 kgf cm 103 ft lbf NOTICE Do not turn the nut HINT At the time of installation after stabilizing the suspension torque the bolt 8 REMOVE LOWER SUSPENSION ARM a Remove the bolt and nut on the rear side of lower suspen sion arm Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut b Remove the front side 3 bolts and lower suspensi...

Page 1982: ...NSION AND AXLE REAR LOWER SUSPENSION ARM SA 75 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 73 HINT After installation check the rear wheel alignment See page SA 9 1981 ...

Page 1983: ...ue Spring O Ring 44 449 32 Bushing Bracket Stabilizer Bar Stabilizer Bar Link 44 449 32 Tailpipe 43 440 32 Heat Insulator Bracket Bushing 18 184 13 18 184 13 44 449 32 SA 76 SUSPENSION AND AXLE REAR STABILIZER BAR 2005 CELICA RM1131U REAR STABILIZER BAR COMPONENTS 1982 ...

Page 1984: ...BAR LINKS a Remove the 2 nuts and stabilizer bar link Torque 44 N m 449 kgf cm 32 ft lbf HINT If the ball joint turns together with the nut use a hexagon 5 mm wrench to hold the stud b Employ the same manner described above to the other side 4 REMOVE STABILIZER BAR BRACKETS AND BUSH INGS a Remove the 2 bolts bracket and bushing Torque 18 N m 184 kgf cm 13 ft lbf HINT At the time of installation in...

Page 1985: ... JOINT FOR ROTA TION CONDITION a As shown in the illustration flip the ball joint stud back and forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 in lbf 1984 ...

Page 1986: ...SA1PK 04 SUSPENSION AND AXLE REAR STABILIZER BAR SA 79 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page SA 77 1985 ...

Page 1987: ... affect the performance of the brake system and result in a driving hazard Replace the parts with parts of the same part number or equivalent S It is very important to keep parts and the area clean when repairing the brake system S If the vehicle is equipped with a mobile communication system refer to the precaution in the IN section 1986 ...

Page 1988: ... BR 4 BR 22 BR 36 BR 28 BR 32 BR 10 BR 18 Brake drag 1 Brake pedal free play Minimum 2 Parking brake lever travel Out of adjustment 3 Parking brake wire Sticking 4 Rear brake shoe clearance Out of adjustment 5 Pad or lining Cracked or distorted 6 Piston Stuck 7 Piston Frozen 8 Anchor tension or return spring Faulty 9 Booster push rod Out of adjustment 10 Vacuum leaks for booster system 11 Master c...

Page 1989: ...81 BR 4 BR 19 BR 33 BR 28 BR 42 BR 19 BR 33 BR 28 BR 42 BR 32 BR 46 BR 19 BR 33 BR 28 BR 42 BR 19 BR 33 BR 28 BR 42 BR 25 BR 39 BR 18 BR 14 Noise from brakes 1 Pad or lining Cracked or distorted 2 Installation bolt Loose 3 Disc Scored 4 Pad support plate Loose 5 Sliding pin Worn 6 Pad or lining Dirty 7 Pad or lining Glazed 8 Anchor tension or return spring Faulty 9 Anti squeal shim Damaged 10 Shoe...

Page 1990: ... reservoir becomes empty bleed the air from the master cylinder a Disconnect the brake lines from the master cylinder SST 09023 00101 b Slowly depress the brake pedal and hold it c Block off the outlet plug with your finger and release the brake pedal d Repeat b and c 3 or 4 times 4 BLEED BRAKE LINE a Connect the vinyl tube to the caliper b Depress the brake pedal several times then loosen the ble...

Page 1991: ... BRAKE BRAKE FLUID BR 5 2005 CELICA RM1131U 5 CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary Fluid SAE J1703 or FMVSS No 116 DOT3 1990 ...

Page 1992: ... the cushion NOTICE When inserting the stop light switch support the pedal from behind so that the pedal is not pushed in h Make a quarter turn clockwise to install the stop light switch NOTICE The turning torque for installing the stop light switch should be 1 5 N m 15 kgf cm 13 ft lbf or less HINT Due to the inverse screw structure if the stop light switch is turned clockwise the stop light swit...

Page 1993: ... PEDAL RESERVE DISTANCE Release the parking brake lever With engine running depress the pedal and measure the pedal reserve distance as shown Pedal reserve distance from asphalt sheet at 490 N 50 kgf 110 2 lbf More than 85 mm 3 35 in If incorrect troubleshoot the brake system 1992 ...

Page 1994: ... 130 9 37 375 27 A T z Bushing z Bushing Brake Pedal Wave Washer Clevis Clevis Pin Clip M T Brake Pedal N m kgf cm ft lbf Specified torque z Non reusable part Lithium soap base glycol grease Pedal Pad Stop Light Switch BR 8 BRAKE BRAKE PEDAL 2005 CELICA RM1131U COMPONENTS 1993 ...

Page 1995: ...N 20 kgf 44 1 lbf 7 8 clicks If incorrect adjust the parking brake 2 IF NECESSARY ADJUST PARKING BRAKE HINT Before adjusting the parking brake make sure that the rear brake shoe clearance has been adjusted For shoe clearance adjustment see step 1 on page BR 45 or see step 2 on page BR 32 a Remove the console box b Loosen the lock nut and turn the adjusting nut until the le ver travel is correct c ...

Page 1996: ... Switch Connector Brake Booster z Gasket Check Valve Bracket Master Cylinder Reservoir 15 155 11 13 130 9 15 155 11 Reservoir Strainer Cap Grommet Grommet M T Hold down Clamp Battery Tray Cylinder Body Reservoir Stopper w o ABS 3 way BR 10 BRAKE BRAKE MASTER CYLINDER 2005 CELICA RM1131U BRAKE MASTER CYLINDER COMPONENTS 1995 ...

Page 1997: ...E LINE a w o ABS Using SST disconnect the 5 brake lines from the master cylinder and 3 way union SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf b w ABS Using SST disconnect the 2 brake lines from the master cylinder SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf 6 REMOVE MASTER CYLINDER a Remove the 2 mounding nuts Torque 13 N m 130 kgf cm 9 ft lbf b w o ABS Pull out the check valve bracke...

Page 1998: ...RESERVOIR a Pull out the reservoir stopper HINT At the time of installation make sure to insert the reservoir stop per through holes of the reservoir and the master cylinder groove b Remove the reservoir and 2 grommets c Remove the cap and strainer from the reservoir 1997 ...

Page 1999: ... the reverse order of removal See page BR 11 HINT S Before installation adjust length of brake booster push rod See page BR 18 S After installation fill the brake reservoir with brake fluid bleed the brake system See page BR 4 and check for leaks S Check and adjust brake pedal See page BR 6 1998 ...

Page 2000: ...start the engine If the pedal goes down slightly operation is normal 2 AIR TIGHTNESS CHECK a Start the engine and stop it after 1 or 2 minutes Depress the brake pedal several times slowly If the pedal goes down farthest the 1st time but gradually rises after the 2nd or 3rd time the booster is air tight b Depress the brake pedal while the engine is running and stop the engine with the pedal depress...

Page 2001: ...ng Switch Connector Clip 25 260 19 13 130 9 15 155 11 15 155 11 3 way 13 130 9 15 155 11 15 155 11 Brake Line 15 155 11 Front LH Brake Line Hold down Clamp Battery Battery Tray w o ABS Lower No 1 Panel Finish Panel z Non reusable part N m kgf cm ft lbf Specified torque z Brake Booster Body Seal BRAKE BRAKE BOOSTER ASSEMBLY BR 15 2005 CELICA RM1131U COMPONENTS 2000 ...

Page 2002: ... Hose z Gasket 15 155 11 13 130 9 15 155 11 Hold down Clamp Battery Battery Tray 19 195 14 15 155 11 ABS Actuator Assembly ECM ECM Bracket Master Cylinder Level Warning Switch Connector Clip ABS Actuator Connector 19 195 14 15 155 11 19 195 14 Harness Clamp Harness Clamp Engine Room Duct 19 195 14 15 155 11 w ABS 25 260 19 z Brake Booster Body Seal BR 16 BRAKE BRAKE BOOSTER ASSEMBLY 2005 CELICA RM...

Page 2003: ...LY See page BR 51 5 REMOVE FRONT LH BRAKE LINE a Using SST and spanner disconnect the brake line from the flexible hose of front LH brake SST 09751 36011 b Pull out the brake line with the grommet from the body 6 REMOVE BRAKE BOOSTER a Remove the lower No 1 panel and finish panel b Remove the return spring clip and clevis pin c Remove the clevis and 4 nuts d Pull out the brake booster and gasket 7...

Page 2004: ...STALL ABS ACTUATOR ASSEMBLY See page BR 52 4 When replacing the brake master cylinder only ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD a Apply chalk to the tip of an accessory tool b Place the accessory tool to the brake booster c Measure the clearance between the brake booster push rod and accessory tool Clearance 0 mm 0 in HINT Adjust the clearance in following cases S If there is a clearance betwee...

Page 2005: ... master cylinder piston NOTICE Be sure to install the brake booster body seal in the correct direction 7 INSTALL MASTER CYLINDER See page BR 13 8 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See page BR 4 9 CHECK FOR FLUID LEAKAGE 10 CHECK AND ADJUST BRAKE PEDAL a Check and adjust the brake pedal See page BR 6 b Install the finish panel and lower No 1 panel 11 DO OPERATIONAL CHECK ...

Page 2006: ...ti squeal Shim Anti squeal Shim Anti squeal Shim Pad Support Plate Inner Anti squeal Shim Inner Pad Pad Support Plate N m kgf cm ft lbf Specified torque Disc brake grease 34 350 25 BRAKE FRONT BRAKE PAD BR 19 2005 CELICA RM1131U FRONT BRAKE PAD COMPONENTS 2005 ...

Page 2007: ...an be used again provided that they have sufficient rebound no deformation cracks or wear and have had all rust dirt and foreign particles cleaned off 6 CHECK DISC THICKNESS AND RUNOUT See page BR 25 7 INSTALL PAD SUPPORT PLATES Install the 2 pad support plates NOTICE Do not assemble the upper and lower pad support plates in reverse 8 INSTALL NEW PADS NOTICE When replacing worn pads the anti squea...

Page 2008: ...e ment HINT If the piston is difficult to push in loosen the bleeder plug and push in the piston while letting some brake fluid escape c Install the caliper d Hold the sliding pin and torque the installation bolts Torque 34 N m 350 kgf cm 25 ft lbf 10 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf 11 DEPRESS BRAKE PEDAL SEVERAL TIMES 12 CHECK THAT FLUID LEVEL IS AT MAX LINE 2007 ...

Page 2009: ...Pad Support Plate Outer Pad Inner Anti squeal Shim Anti squeal Shim 8 3 85 74 in lbf Bleeder Plug 34 350 25 34 350 25 Piston Seal Piston Boot N m kgf cm ft lbf Specified torque z Non reusable part Lithium soap base glycol grease Disc brake grease z Gasket Bleeder Plug Cap Pad Wear Indicator Plate Union Bolt BR 22 BRAKE FRONT BRAKE CALIPER 2005 CELICA RM1131U FRONT BRAKE CALIPER COMPONENTS 2008 ...

Page 2010: ...then disconnect the flexible hose from the caliper Torque 30 N m 310 kgf cm 22 ft lbf HINT At the time of installation install the flexible hose lock securely in the lock hole in the caliper b Use a container to catch the brake fluid as it drains out 3 REMOVE CALIPER a Hold the sliding pin and remove the 2 installation bolts Torque 34 N m 350 kgf cm 25 ft lbf b Remove the caliper from the torque p...

Page 2011: ... place your fingers in front of the piston when using compressed air 3 REMOVE PISTON SEAL Using a screwdriver remove the piston seal from the cylinder 4 REMOVE BLEEDER PLUG CAP AND BLEEDER PLUG 5 REMOVE SLIDING PINS AND DUST BOOTS a Remove the 2 sliding pins from the torque plate b Using a screwdriver and hammer tap out the 2 dust boots HINT At the time of reassembly use a 19 mm socket wrench and ...

Page 2012: ...f the disc s runout is maximum value or greater check the bear ing play in the axial direction and check the axle hub runout See page SA 13 If the bearing play and axle hub runout are not abnormal adjust the disc runout or grind it on a On car brake lathe 4 IF NECESSARY ADJUST DISC RUNOUT a Remove the 2 bolts and torque plate from the knuckle b Remove the hub nuts and the disc Reinstall the disc i...

Page 2013: ...RAKE FRONT BRAKE CALIPER 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 24 NOTICE Apply lithium soap base glycol grease to the parts indicated by arrows See page BR 22 2012 ...

Page 2014: ...PER BR 27 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BR 23 HINT S After installation fill the brake reservoir with brake fluid and bleed brake system See page BR 4 S Check for leaks 2013 ...

Page 2015: ...85 73 in lbf 10 100 7 z C Washer Adjuster Front Shoe Anchor Spring Brake Drum Adjuster z Non reusable part High temperature grease Lithium soap base glycol grease Adjusting Lever Spring z Cup Boot Piston Cap Plug Return Spring N m kgf cm ft lbf Specified torque Cap Shoe Hold Down Spring Pin BR 28 BRAKE REAR DRUM BRAKE 2005 CELICA RM1131U REAR DRUM BRAKE COMPONENTS 2014 ...

Page 2016: ...le in the backing plate c Using another screwdriver reduce the brake shoe adjust er by turning the adjusting wheel 4 REMOVE FRONT SHOE a Using SST disconnect the adjuster spring from the rear shoe SST 09703 30010 b Using needle nose pliers remove the anchor spring c Using SST remove the cap shoe hold down spring and pin from the front shoe SST 09718 00010 d Remove the adjuster and adjuster spring ...

Page 2017: ...from the rear shoe 7 REMOVE WHEEL CYLINDER a Using SST disconnect the brake line Use container to catch the brake fluid SST 09751 36011 Torque 15 N m 155 kgf cm 11 ft lbf b Remove the 2 bolts and the wheel cylinder Torque 10 N m 100 kgf cm 7 ft lbf 8 DISASSEMBLE WHEEL CYLINDER a Remove the 2 boots from the wheel cylinder b Remove the 2 pistons from the wheel cylinder c Remove the spring from the w...

Page 2018: ... uneven wear replace the brake shoes HINT If brake shoes need to be replaced they must be replaced as a set 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using a brake drum gauge or equivalent measure the inside di ameter of the drum Standard inside diameter 200 0 mm 7 874 in Maximum inside diameter 201 0 mm 7 913 in If the drum is scored or worn the brake drum may be lathed to the maximum inside diameter ...

Page 2019: ...ation of the rear brake b Adjust the adjuster length to the as short as possible c Install the brake drum d Pull the parking brake lever all the way up until a clicking sound can no longer be heard 2 CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM a Remove the brake drum b Measure the brake drum inside diameter and diameter of the brake shoes Check that the difference between the diameters is the cor...

Page 2020: ...R0QJ 09 F09540 Disc brake grease Anti squeal Shim Inner Pad Pad Guide Pin Outer Pad Anti squeal Shim Clip Anti rattle Spring BRAKE REAR BRAKE PAD BR 33 2005 CELICA RM1131U REAR BRAKE PAD COMPONENTS 2019 ...

Page 2021: ...de pins 4 REMOVE PADS AND ANTI SQUEAL SHIMS a Remove the 2 pads b Remove the anti squeal shim from each pad 5 CHECK DISC THICKNESS AND RUNOUT See page BR 39 6 INSTALL NEW PADS NOTICE When replacing worn pads the anti squeal shims must be replaced together with the pads a Apply disc brake grease to inside of anti squeal shims See page BR 33 b Install the anti squeal shim on each pad c Draw out a sm...

Page 2022: ...ook the spring lower portion to the center hole of the brake pad 9 FIX GUIDE PINS WITH CLIP a Insert the clip end into the hole of the guide pin No 1 b Insert the other clip end into the hole of the guide pin No 2 NOTICE The clip should be fully inserted into the guide pin No 1 and No 2 If not the guide pins will come off and the brake cali per will be broken 10 INSTALL REAR WHEEL Torque 103 N m 1...

Page 2023: ...ithium soap base glycol grease Disc brake grease Bleeder Plug 47 475 34 30 310 22 8 3 85 74 in lbf Anti squeal Shim Outer Pad Set Ring Clip Piston Boot Anti rattle Spring Anti rattle Spring Piston Seal Dust Boot Brake Caliper Sliding Bushing z Gasket BR 36 BRAKE REAR BRAKE CALIPER 2005 CELICA RM1131U REAR BRAKE CALIPER COMPONENTS 2022 ...

Page 2024: ...sconnect the flexible hose from the caliper Torque 30 N m 310 kgf cm 22 ft lbf HINT At the time of installation insert the flexible hose lock securely in the lock hole in the caliper b Use a container to catch the brake fluid as it drains out 3 REMOVE CALIPER a Remove the 2 installation bolts and caliper Torque 47 N m 475 kgf cm 34 ft lbf b Remove the caliper from the torque plate 4 REMOVE 2 PADS ...

Page 2025: ... cylinder boot 2 REMOVE PISTON a Put a piece of cloth or an equivalent between the piston and caliper b Use compressed air to remove the piston from the cylin der CAUTION Do not place your fingers in front of the piston when using compressed air 3 REMOVE PISTON SEAL FROM CYLINDER Using a screwdriver remove the piston seal 4 REMOVE 2 SLIDING BUSHINGS AND 3 DUST BOOTS 2024 ...

Page 2026: ...om the outside edge Maximum disc runout 0 15 mm 0 0059 in If the disc s runout is at the maximum value or greater check the bearing play is in the axial direction and check the axle hub run out See page SA 56 If the bearing play and axle hub runout are not abnormal adjust the disc runout or grind it on a On car brake lathe 4 IF NECESSARY ADJUST DISC RUNOUT a Remove the hub nuts and the disc Reinst...

Page 2027: ...KE REAR BRAKE CALIPER 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 38 NOTICE Apply lithium soap base glycol grease to the parts indicated by the arrows See page BR 36 2026 ...

Page 2028: ... BR 41 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BR 37 HINT S After installation fill the brake reservoir with brake fluid and bleed the brake system See page BR 4 S Check for leaks 2027 ...

Page 2029: ... Spring Return Spring Parking Brake Shoe Lever Rear Shoe High temperature grease N m kgf cm ft lbf Specified torque 47 475 34 Disc Pin Brake Caliper Assembly Front Shoe Plug Shoe Hold down Spring BR 42 BRAKE PARKING BRAKE 2005 CELICA RM1131U PARKING BRAKE COMPONENTS 2028 ...

Page 2030: ...per b Suspend the disc brake securely Ensure that the hose is not stretched 3 REMOVE DISC Release the parking brake lever and remove the disc HINT If the disc cannot be removed easily turn the shoe adjuster until the wheel turns freely 4 REMOVE SHOE RETURN SPRINGS AND TENSION SPRING Using needle nose pliers remove the 2 shoe return springs and tension spring 5 REMOVE SHOE STRUT 6 REMOVE FRONT SHOE...

Page 2031: ...ove the shoe hold down spring and pin from the rear shoe SST 09718 00010 b Disconnect the rear shoe from the parking brake shoe le ver and remove rear shoe 8 REMOVE PARKING BRAKE SHOE LEVER Using needle nose pliers disconnect the parking brake cable from the parking brake shoe lever 2030 ...

Page 2032: ...e 3 MEASURE DISC INSIDE DIAMETER Using a brake drum gauge or equivalent measure the inside di ameter of the disc Standard inside diameter 173 0 mm 6 811 in Maximum inside diameter 174 0 mm 6 850 in Replace the disc if the inside diameter is at the maximum value or more Replace the disc or grind it with a lathe if the disc is scored or is worn unevenly 4 INSPECT PARKING BRAKE LINING AND DISC FOR PR...

Page 2033: ...ove the hole plug c Turn the adjuster and expand the shoes until the disc locks d Return the adjuster 8 notches e Install the hole plug 2 SETTLING PARKING BRAKE SHOES AND DISC a Drive the vehicle at about 50 km h 31 mph on a safe lev el and dry road b With the parking brake release button pushed in pull on the lever with 98 N 10 kgf 19 8 lbf of force c Drive the vehicle for about 400 meters 0 25 m...

Page 2034: ...d pressure 2 450 kPa 25 0 kgf cm2 355 psi 2 450 kPa 25 0 kgf cm2 355 psi 7 850 kPa 80 0 kgf cm2 1 139 psi 3 800 kPa 38 8 kgf cm2 551 psi 2ZZ GE engine Master cylinder fluid pressure Rear brake caliper fluid pressure 2 450 kPa 25 0 kgf cm2 355 psi 2 450 kPa 25 0 kgf cm2 355 psi 7 850 kPa 80 0 kgf cm2 1 139 psi 4 450 kPa 45 4 kgf cm2 646 psi When inspecting the fluid pressure inspect the left font a...

Page 2035: ... for more than 5 seconds con tinuously When operating it continuously set the interval of more than 20 seconds e Turn the motor relay OFF and release the brake pedal 3 INSPECT RIGHT FRONT WHEEL OPERATION NOTICE Never turn ON the solenoid which is not described below a With the brake pedal depressed perform the following operations b Turn the SFRH and SFRR solenoid ON simultaneously and check that ...

Page 2036: ...005 CELICA RM1131U 4 INSPECT OTHER WHEEL OPERATION As in the same procedure check the solenoids of other wheels HINT Left front wheel SFLH SFLR Right rear wheel SRRH SRRR Left rear wheel SRLH SRLR 5 CLEAR DTC See page DI 836 2035 ...

Page 2037: ...r N m kgf cm ft lbf Specified torque z Non reusable part 19 195 14 15 155 11 19 195 14 Harness Clamp Harness Clamp ABS Actuator Connector 19 195 14 15 155 11 To Front Left To Front Right 15 155 11 To Rear Left 15 155 11 To Rear Right 15 155 11 From Master Cylinder Front From Master Cylinder Rear ECM Bracket 13 130 9 5 4 55 48 in lbf 19 195 14 15 155 11 15 155 11 BR 50 BRAKE ABS ACTUATOR 2005 CELIC...

Page 2038: ...4 DISCONNECT ABS ACTUATOR CONNECTOR Pull the release bar and disconnect the ABS actuator connec tor 5 DISCONNECT BRAKE LINES Using SST disconnect the 6 brake lines SST 09023 00101 Torque 15 N m 155 kgf cm 11 ft lbf HINT S When disconnecting the brake lines Use tags or make a memo to identify the place to reconnect See page BR 50 S At the time of installation connect each brake line to the correct ...

Page 2039: ...UATOR 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BR 51 HINT S After installation fill the brake reservoir with brake fluid and bleed brake system See page BR 4 S Check for leaks 2038 ...

Page 2040: ...BR0R0 08 F09768 8 0 82 71 in lbf Front Speed Sensor 8 0 82 71 in lbf Resin Clip N m kgf cm ft lbf Specified torque BRAKE FRONT SPEED SENSOR BR 53 2005 CELICA RM1131U FRONT SPEED SENSOR COMPONENTS 2039 ...

Page 2041: ... a Remove the 2 clamp bolts holding the sensor harness from the body and shock absorber Torque 8 0 N m 82 kgf cm 71 in lbf b Remove the speed sensor installation bolt from the steer ing knuckle Torque 8 0 N m 82 kgf cm 71 in lbf NOTICE At the time of installation please refer to the following item S There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be ...

Page 2042: ...BR0R2 04 BRAKE FRONT SPEED SENSOR BR 55 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BR 54 AFTER INSTALLATION CHECK SPEED SENSOR SIGNAL See page DI 836 2041 ...

Page 2043: ...BR0R3 08 F09769 8 0 82 71 in lbf N m kgf cm ft lbf Specified torque Rear Speed Sensor 19 195 14 BR 56 BRAKE REAR SPEED SENSOR 2005 CELICA RM1131U REAR SPEED SENSOR COMPONENTS 2042 ...

Page 2044: ...031 b Mount the rear axle hub in a soft jaw vise NOTICE Replace the axle hub assembly if it is dropped or a strong shock is given to it c Using SST and 2 bolts Diameter 12 mm Pitch 1 5 mm remove the speed sensor SST 09520 00031 09520 00040 09521 00020 09950 00020 NOTICE S If a damage is inflicted to the sensor rotor replace the axle hub assembly S Do not scratch the contacting surface of axle hub ...

Page 2045: ...5 CELICA RM1131U c Remove the 2 clamp bolts holding the sensor harness from the lower arm and body Torque Lower arm side 19 N m 195 kgf cm 14 ft lbf Body side 8 0 N m 82 kgf cm 71 in lbf d Replace the sensor wire harness with the grommet 2044 ...

Page 2046: ...ost downward position under the on vehicle condition c Using SST and a press install a new speed sensor to the axle hub SST 09214 76011 NOTICE S Do not tap the speed sensor with a hammer directly S Check that there should be no foreign objects on the speed sensor detection portion S Press in the speed sensor straight and slowly 2 INSTALL SPEED SENSOR WITH REAR AXLE See page SA 60 3 CONNECT SPEED S...

Page 2047: ...The CELICA is equipped with an SRS Supplemental Restraint System such as the driver air bag and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing including removal or installation of parts inspection or replace ment be sure to read the precautionar...

Page 2048: ...ncorrect 5 Steering system joints Worn 6 Suspension arm ball joints Worn 7 Steering column Binding 8 Power steering vane pump 9 Power steering gear SA 3 SR 5 SR 3 SA 5 SA 49 SR 24 SR 35 Poor return 1 Tires Improperly inflated 2 Front wheel alignment Incorrect 3 Steering column Binding 4 Power steering gear SA 3 SA 5 SR 35 Excessive play 1 Steering system joints Worn 2 Suspension arm ball joints Wo...

Page 2049: ...y defect has been found replace the drive belt HINT S Cracks on the rib side of a belt are considered acceptable If the missing chunks from the ribs are found on the drive belt it should be replaced S After installing a drive belt check that it fits properly in the ribbed grooves S Check with your hand to confirm that the drive belt has not slipped out of the groove on the bottom of the pulley 204...

Page 2050: ... START ENGINE Run the engine at idle for a few minutes 6 TURN STEERING WHEEL a With the engine idling turn the steering wheel to left or right full lock position and keep it there for 2 3 seconds then turn the steering wheel to the opposite full lock posi tion and keep it there for 2 3 seconds b Repeat a several times 7 STOP ENGINE 8 CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled...

Page 2051: ... fluid is cold check that it is within the COLD LEVEL range c Start the engine and run it at idle d Turn the steering wheel from lock to lock several times to boost fluid temperature Fluid temperature 80 C 176 F e Check for foaming or emulsification If there is foaming or emulsification bleed power steering sys tem See page SR 4 f With the engine idling measure the fluid level in the oil reservoir...

Page 2052: ...1 01010 09641 01030 09641 01060 NOTICE Check that the valve of the SST is in the open position c Bleed the power steering system See page SR 4 d Start the engine and run it at idle e Turn the steering wheel from lock to lock several times to boost fluid temperature Fluid temperature 80 C 176 F f With the engine idling close the valve of the SST and ob serve the reading on the SST Minimum fluid pre...

Page 2053: ...90 kPa 5 kgf cm2 71 psi or less NOTICE Do not turn the steering wheel i With the engine idling and valve fully opened turn the steering wheel to full lock Minimum fluid pressure 7 355 kPa 75 kgf cm2 1 067 psi NOTICE S Do not maintain lock position for more than 10 se conds S Do not let the fluid temperature become too high j Disconnect the SST SST 09640 10010 09641 01010 09641 01030 09641 01060 k ...

Page 2054: ...m freeplay 30 mm 1 18 in 2 CHECK STEERING EFFORT a Center the steering wheel b Remove the steering wheel pad See page SR 13 c Start the engine and run it at idle d Measure the steering effort in both directions Steering effort Reference 6 5 N m 65 kgf cm 58 in lbf HINT Take the tire type pressure and contact surface into consider ation before making your diagnosis e Install the steering wheel set ...

Page 2055: ...CEDURES HINT This is the repair procedure for steering off center 1 INSPECT STEERING WHEEL OFF CENTER a Apply masking tape on the top center of the steering wheel and steering column upper cover b Drive the vehicle in a straight line for 100 meters at a constant speed of 35 mph 56 km h and hold the steer ing wheel to maintain the course c Draw a line on the masking tape as shown in the illustra ti...

Page 2056: ... of the steering angle 2 ADJUST STEERING ANGLE a Draw a line on the RH and LH tie rod and rack ends where it can easily be seen b Using a paper gauge measure the distance from RH and LH tie rod ends to the rack end screws HINT S Measure the RH side and LH side S Make a note of the measured values c Remove the RH and LH boot clips from the rack boots d Loosen the RH and LH lock nuts e Turn the RH a...

Page 2057: ...aft Assembly Column Hole Cover Silencer Sheet Wiper and Washer Switch Spiral Cable Column Lower Cover w Speed control main switch 8 8 90 78 in lbf w Transmission shift switch A T Torx Screw 8 8 90 78 in lbf Torx Screw Column Upper Cover 35 360 26 35 360 26 35 360 26 21 210 15 21 210 15 Hood Lock Release Lever Instrument Finish Panel N m kgf cm ft lbf Specified torque Steering Wheel 50 510 37 STEER...

Page 2058: ... Bracket Spacer No 1 Support Collar z z No 1 Support Collar z Main Shaft Bushing Tilt Steering Support Main Shaft Assembly Stopper No 1 Support Reinforce No 2 Tilt Lever Lock Bolt Adjusting Nut Tilt Lever z Snap Ring z See page SR 19 15 150 11 5 4 55 48 in lbf N m kgf cm ft lbf Specified torque z Non reusable part Molybdenum disulfide lithium base grease SR 12 STEERING TILT STEERING COLUMN 2005 CE...

Page 2059: ... the upper surface of the pad facing upward S Never disassemble the wheel pad NOTICE When removing the wheel pad take care not to pull the air bag wire harness 2 REMOVE STEERING WHEEL a Disconnect the connector b Remove the steering wheel set nut c Place matchmarks on the steering wheel and main shaft assembly d Using SST remove the steering wheel SST 09950 50013 09951 05010 09952 05010 09953 0502...

Page 2060: ...above to the wiper and washer switch e Remove the spiral cable NOTICE Do not disassemble the spiral cable or apply oil to it 8 A T REMOVE KEY INTERLOCK CABLE With the key in ACC push the claw and pull out the key interlock cable 9 REMOVE COLUMN HOLE COVER SILENCER SHEET 10 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY a Place matchmarks on the No 2 intermediate shaft as sembly and intermediate exte...

Page 2061: ...rews b Disengage the secondary locking device of the connec tor c Release the locking lug of the terminal 1 horn switch ter minal and pull the terminal out of the rear d Remove the speed control main switch assembly 15 w Transmission shift switch and speed control main switch REMOVE TRANSMISSION SHIFT SWITCH AS SEMBLY AND SPEED CONTROL MAIN SWITCH AS SEMBLY FROM STEERING WHEEL a Remove the 2 screw...

Page 2062: ...bolts c Using a screw extractor remove the 2 bolts column up per bracket and column upper clamp 2 REMOVE TILT STEERING SUPPORT Remove the bolt and tilt steering support 3 REMOVE BRACKET SPACER AND 2 NO 1 SUPPORT COLLARS a Using an extension bar and a hammer tap out the bracket spacer b Using a screwdriver remove the 2 No 1 support collars 4 REMOVE TILT LEVER AND BREAK AWAY BRACKET a Remove the til...

Page 2063: ... is left handed one d Remove the No 2 support collar from the break away bracket 5 REMOVE MAIN SHAFT BUSHING Using a screwdriver and hammer tap out the main shaft bush ing 6 REMOVE MAIN SHAFT ASSEMBLY a Using a snap ring expander remove the snap ring on the upper side b Remove the main shaft assembly c Using a snap ring expander remove the snap ring on the lower side 2062 ...

Page 2064: ...CC position 3 INSPECT IGNITION SWITCH See page BE 15 4 IF NECESSARY REPLACE IGNITION SWITCH a Remove the 2 screws and ignition switch from the column upper bracket b Install a new ignition switch with the 2 screws 5 INSPECT KEY UNLOCK WARNING SWITCH See page BE 15 6 IF NECESSARY REPLACE KEY UNLOCK WARNING SWITCH a Slide the key unlock warning switch out of the column up per bracket b Slide a new k...

Page 2065: ...ew bushing with molybdenum disulfide lithium base grease b Using SST and a hammer tap in the main shaft bushing SST 09608 04031 4 INSTALL BREAK AWAY BRACKET AND TILT LEVER a Install the No 2 support collar to the break away bracket b Install the break away bracket tilt lever lock bolt stopper and tilt lever HINT Align the holes in the column tube with the projections of the tilt lever lock bolt an...

Page 2066: ... NO 1 SUPPORT COLLARS AND BRACK ET SPACER a Install 2 new No 1 support collars HINT Install the white support collar to the RH side black support col lar to the LH side b Using an extension bar and a hammer drive in the brack et spacer 6 INSTALL TILT STEERING SUPPORT Install the tilt steering support with the bolt Torque 15 N m 155 kgf cm 11 ft lbf NOTICE Make sure that the tilt steering support i...

Page 2067: ...nstall the 2 screws 3 w Transmission shift switch and speed control main switch INSTALL TRANSMISSION SHIFT SWITCH ASSEMBLY AND SPEED CONTROL MAIN SWITCH ASSEMBLY TO STEERING WHEEL a Install the transmission shift switch assembly and speed control main switch assembly b Push the terminal 1 horn switch terminal into the con nector c Engage the secondary locking device of the connector d Install the ...

Page 2068: ...o the light control switch and headlight dimmer switch until the claw is latched c Employ the same manner described above to the wiper and washer switch d Connect the airbag connector to the spiral cable e Connect the 3 connectors to the spiral cable light control switch and headlight dimmer switch and wiper and wash er switch 10 INSTALL COLUMN UPPER AND LOWER COVERS Install the column upper and l...

Page 2069: ...t the connector 16 INSTALL STEERING WHEEL PAD NOTICE S Never use airbag parts from another vehicle When replacing parts replace with new ones S Make sure the wheel pad is installed with the speci fied torque S If the wheel pad has been dropped or there are cracks dents or other defects in the case or connec tor replace the wheel pad with a new one S When installing the wheel pad take care that the...

Page 2070: ...Vane Pump Assembly Drive Belt Center Engine Under Cover RH Engine Under Cover N m kgf cm ft lbf Specified torque For use with SST 44 450 33 40 410 30 Clip 7 8 80 69 in lbf 37 370 27 SR 24 STEERING POWER STEERING VANE PUMP 2005 CELICA RM1131U POWER STEERING VANE PUMP COMPONENTS 2069 ...

Page 2071: ...Shaft with Vane Pump Pulley Vane Plate Cam Ring Side Plate O Ring Oil Seal 12 120 9 43 440 32 22 220 16 69 700 51 22 220 16 1ZZ FE engine 2ZZ FE engine x 10 N m kgf cm ft lbf Specified torque Non reusable part Power steering fluid z O Ring z z O Ring z z O Ring z Front Housing z Oil Pressure Switch 21 210 15 STEERING POWER STEERING VANE PUMP SR 25 2005 CELICA RM1131U 2070 ...

Page 2072: ...ise and remove the drive belt 3 DISCONNECT SUCTION HOSE Remove the clip and disconnect the suction hose NOTICE Take care not to spill fluid on the drive belt 4 DISCONNECT PRESSURE FEED TUBE a Using SST disconnect the pressure feed tube SST 09023 38401 b Remove the bolt and disconnect the pressure feed tube clamp 5 DISCONNECT OIL PRESSURE SWITCH CONNECTOR 6 REMOVE PS VANE PUMP ASSEMBLY Remove the 2...

Page 2073: ...ve the pressure port union flow control valve and spring b Remove the O ring from the pressure port union 4 REMOVE OIL PRESSURE SWITCH NOTICE Be careful not to drop the oil pressure switch If the oil pressure switch is dropped or strongly damaged re place it with a new one 5 REMOVE REAR HOUSING a Remove the bolt and rear bracket b Remove the 4 bolts and rear housing c Remove the O ring from the re...

Page 2074: ...arance 0 021 0 043 mm 0 0008 0 0017 in Maximum clearance 0 07 mm 0 0028 in If it is more than the maximum replace the front housing and vane pump shaft 2 INSPECT VANE PUMP ROTOR AND VANE PLATES a Using a micrometer measure the height thickness and length of the 10 vane plates Minimum height 7 6 mm 0 299 in Minimum thickness 1 405 mm 0 0553 in Minimum length 11 993 mm 0 4722 in b Using a feeler gau...

Page 2075: ...248 0 47256 1 44345 32110 11 999 12 001 0 47240 0 47248 2 44345 32120 11 997 11 999 0 47232 0 47240 3 44345 32130 11 995 11 997 0 47224 0 47232 4 44345 32140 11 993 11 995 0 47216 0 47224 3 INSPECT FLOW CONTROL VALVE a Coat the flow control valve with power steering fluid and check that it falls smoothly into the valve hole of the front housing by its own weight b Check the flow control valve for ...

Page 2076: ... STEERING POWER STEERING VANE PUMP 2005 CELICA RM1131U 4 INSPECT SPRING Using vernier calipers measure the free length of the spring Minimum free length 35 8 mm 1 409 in If it is not within the specification replace the spring 2075 ...

Page 2077: ...EPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the bushing of the front housing b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 00280 09950 70010 09951 07100 NOTICE Make sure that the oil seal is installed facing in the correct direction 2076 ...

Page 2078: ...L CAM RING Align the dent of the cam ring with the dent of the side plate and install the cam ring with the inscribed mark facing outward 5 INSTALL VANE PUMP ROTOR a Install the vane pump rotor with the inscribed mark facing outward b Install a new snap ring to the vane pump shaft 6 INSTALL 10 VANE PLATES Install the 10 vane plates with the round end facing outward 7 INSTALL REAR HOUSING a Coat a ...

Page 2079: ...R 24 c Coat a new O ring with power steering fluid and install it to the pressure port union d Install the pressure port union Torque 69 N m 700 kgf cm 51 ft lbf 10 INSTALL SUCTION PORT UNION a Coat a new O ring with power steering fluid and install it to the suction port union b Install the suction port union with the bolt Torque 12 N m 120 kgf cm 9 ft lbf 11 MEASURE PS VANE PUMP ROTATING TORQUE ...

Page 2080: ...D TUBE a Connect the pressure feed tube clamp with the bolt Torque 7 8 N m 80 kgf cm 69 in lbf b Using SST connect the pressure feed tube SST 09023 38401 Torque 40 N m 410 kgf cm 30 ft lbf HINT S Use a torque wrench with a fulcrum length of 345 mm 11 81 in S This torque value is effective in case that SST is parallel to a torque wrench 4 CONNECT SUCTION HOSE Connect the suction hose with the clip ...

Page 2081: ...diate Extension 44 450 33 40 410 30 35 360 26 58 590 43 58 590 43 58 590 43 49 500 36 7 8 80 69 in lbf 49 500 36 Cotter Pin 13 130 9 64 650 47 Cotter Pin 87 890 64 64 650 47 44 450 33 157 1 600 116 52 530 38 157 1 600 116 44 450 33 157 1 600 116 39 400 29 52 530 38 52 530 38 142 1 450 105 N m kgf cm ft lbf Specified torque For use with SST z Non reusable part 58 590 43 z z 13 130 9 157 1 600 116 S...

Page 2082: ...750 54 83 850 61 62 630 46 Oil Seal Rack End 83 850 61 62 630 46 Wire z Clip Lock Nut 74 750 54 Tie Rod End N m kgf cm ft lbf Specified torque Non reusable part Molybdenum disulfide lithium base grease Power steering fluid For use with SST z z z z z Rack Boot z Claw Washer z Claw Washer z SR 36 STEERING POWER STEERING GEAR 2005 CELICA RM1131U 2081 ...

Page 2083: ...l 25 250 18 23 230 17 74 750 54 25 250 18 23 230 17 25 250 18 23 230 17 25 250 18 23 230 17 Control Valve Assembly N m kgf cm ft lbf Specified torque Non reusable part Precoated part Molybdenum disulfide lithium base grease Power steering fluid For use with SST L z z z z z z L Bearing Guide Nut 40 410 30 Bearing z Union Seat z STEERING POWER STEERING GEAR SR 37 2005 CELICA RM1131U 2082 ...

Page 2084: ...EL PAD See page SR 13 3 REMOVE STEERING WHEEL See page SR 13 4 REMOVE RH CENTER AND LH ENGINE UNDER COV ERS 5 DISCONNECT RH AND LH TIE ROD ENDS See page SA 13 6 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY See page SR 13 7 DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST disconnect the pressure feed and return tubes SST 09023 38401 8 DISCONNECT TUBE CLAMP Remove the bolt and disconnect the tube...

Page 2085: ... BALL JOINT FROM LOWER SUSPENSION ARM See page SA 43 13 DISCONNECT STABILIZER BAR a Remove the nut and disconnect the stabilizer bar b Employ the same manner described above to the other side 14 DISCONNECT ENGINE REAR MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Remove the bolt bolt A and 3 nuts and disconnect the engine rear mount insulator and front suspension member 15 DISCONNECT ENGINE FRONT MO...

Page 2086: ...hmarks on the intermediate extension and control valve shaft c Remove the bolt and intermediate extension 19 REMOVE ENGINE REAR MOUNT INSULATOR AND ENGINE REAR MOUNT BRACKET a Remove the through bolt and engine rear mount insulator b Remove the 3 bolts and engine rear mount bracket 2085 ...

Page 2087: ...AND LOCK NUTS a Place matchmarks on the tie rod end and rack end b Loosen the lock nut and remove the tie rod end and lock nut c Employ the same manner described above to the other side 4 REMOVE RH AND LH CLIPS WIRES AND RACK BOOTS a Using needle nose pliers loosen the wire b Remove the clip wire and rack boot NOTICE Be careful not to damage the boot HINT Mark the RH and LH rack boots c Employ the...

Page 2088: ... RACK GUIDE SUB AS SEMBLY 7 REMOVE RACK HOUSING CAP a Remove the rack housing cap b Remove the O ring from the rack housing cap 8 REMOVE CONTROL VALVE ASSEMBLY Pull out the control valve assembly NOTICE Be careful not to damage the oil seal lip 9 REMOVE CYLINDER END STOPPER a Using snap ring pliers remove the snap ring b Pull out the cylinder end stopper 10 REMOVE STEERING RACK AND OIL SEAL Using ...

Page 2089: ... SR 43 2005 CELICA RM1131U INSPECTION NOTICE When using a vise do not overtighten it INSPECT STEERING RACK a Using a dial indicator check the rack for runout teeth wear and damage Maximum runout 0 1 mm 0 004 in b Check the back surface for wear and damage 2088 ...

Page 2090: ...9617 35020 Torque 40 N m 410 kgf cm 30 ft lbf 2 IF NECESSARY REPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the rack housing cap b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 00210 09951 00340 09952 06010 09950 70010 09951 07100 NOTICE Make sure that the oi...

Page 2091: ...e correct direction 4 IF NECESSARY REPLACE BEARING a Using a punch and a hammer tap out the bearing b Coat a new bearing with molybdenum disulfide lithium base grease c Using a brass bar and a hammer tap in the bearing 5 IF NECESSARY REPLACE 2 UNION SEATS a Using a screw extractor remove the union seat from the rack housing b Using a hammer and an extension bar lightly tap in a new union seat NOTI...

Page 2092: ...e careful not to overexpand the teflon ring d Coat the teflon ring with power steering fluid e Install the teflon ring to the steering rack and settle it down with your fingers 7 IF NECESSARY REPLACE 4 TEFLON RINGS a Using a screwdriver remove the 4 teflon rings from the control valve assembly NOTICE Be careful not to damage the grooves for the teflon rings b Expand 4 new teflon rings with your fi...

Page 2093: ...OWER STEERING GEAR SR 47 2005 CELICA RM1131U e Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly SST 09631 20081 NOTICE Be careful not to damage the teflon rings 2092 ...

Page 2094: ...id b Install the oil seal to SST and press them into the rack housing SST 09950 60010 09951 00240 09951 00400 09952 06010 09950 70010 09951 07360 NOTICE S Make sure that the oil seal is installed facing in the correct direction S Take care that the oil seal does not get reversed as you install it 3 INSTALL STEERING RACK a Install SST to the rack SST 09631 20051 HINT If necessary scrape the burrs o...

Page 2095: ...SST 09612 22011 b Using snap ring pliers install a new snap ring to the rack housing 6 AIR TIGHTNESS TEST a Install SST to the rack housing SST 09631 12071 b Apply 53 kPa 400 mmHg 15 75 in Hg of vacuum for about 30 seconds c Check that there is no change in the vacuum If there is a change in the vacuum check the installation of the oil seals 7 INSTALL CONTROL VALVE ASSEMBLY NOTICE Be careful not t...

Page 2096: ...ing cap Torque 25 N m 250 kgf cm 18 ft lbf c Return the rack guide spring cap 12 d Using SST turn the control valve shaft right and left 1 or 2 times SST 09616 00011 e Loosen the rack guide spring cap until the rack guide spring is not functioning f Using SST and torque wrench tighten the rack guide spring cap until the preload is within the specification SST 09616 00011 Preload turning 0 9 1 3 N ...

Page 2097: ...hown in the illustra tion HINT Use a torque wrench with a fulcrum length of 380 mm 14 96 in c Using a brass bar and a hammer stake the washer NOTICE Avoid any impact on the steering rack d Employ the same manner described above to the other side 12 INSTALL RH AND LH RACK BOOTS WIRES AND CLIPS a Ensure that the steering rack hole is not clogged with grease HINT If the hole is clogged the pressure i...

Page 2098: ... Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned b After adjusting toe in torque the nut See page SA 5 Torque 74 N m 750 kgf cm 54 ft lbf c Employ the same manner described above to the other side 14 INSTALL 2 TURN PRESSURE TUBES Using SST install the 2 turn pressure tubes SST 09023 38201 Torque 23 N m 230 kgf cm 17 ft lbf HINT S Use a torque wrench with a ful...

Page 2099: ...SUSPENSION ARM AND PS GEAR ASSEMBLY Install the front suspension member with lower suspension arm and PS gear assembly with the 6 bolts bolt C D and E Torque Bolt C 157 N m 1 600 kgf cm 116 ft lbf Bolt D 157 N m 1 600 kgf cm 116 ft lbf Bolt E 39 N m 400 kgf cm 29 ft lbf 4 CONNECT ENGINE FRONT MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Connect the engine front mount insulator and front suspension ...

Page 2100: ...CT PRESSURE FEED AND RETURN TUBES Using SST connect the pressure feed and return tubes SST 09023 38400 Torque 40 N m 410 kgf cm 30 ft lbf HINT S Use a torque wrench with a fulcrum length of 345 mm 13 58 in S This torque value is effective in case that SST is parallel to a torque wrench 13 CONNECT NO 2 INTERMEDIATE SHAFT ASSEMBLY See page SR 21 14 CONNECT RH AND LH TIE ROD ENDS See page SA 17 15 IN...

Page 2101: ...AR SR 55 2005 CELICA RM1131U 20 CHECK STEERING WHEEL CENTER POINT 21 TORQUE STEERING WHEEL SET NUT Torque 50 N m 510 kgf cm 37 ft lbf 22 INSTALL STEERING WHEEL PAD See page SR 21 23 CHECK FRONT WHEEL ALIGNMENT See page SA 5 2100 ...

Page 2102: ...passenger airbag assembly side airbag assembly airbag sensor assembly front airbag sen sor side airbag sensor assembly and door side airbag sensor should be inspected See page RS 14 RS 28 RS 42 RS 54 RS 59 RS 64 and RS 69 S Before repairs remove the airbag sensor if shocks are likely to be applied to the sensor during repairs S Never use SRS parts from another vehicle When replacing parts replace ...

Page 2103: ... and bag of the SRS are stored in the front passen ger airbag assembly and cannot be disassembled The inflater contains a squib igniter charge gas generator etc and in flates the bag when instructed by the airbag sensor assembly 4 SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled The inflater contains a squib igniter ...

Page 2104: ...or assembly cannot be disas sembled 8 FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the side members The sensor unit is a mechanical type When the sen sor detects deceleration force above a predetermined limit contact is made in the sensor sending a signal to the airbag sensor assembly The front airbag sensor cannot be disas sembled 9 SIDE AIRBAG SENSOR ASSEMBLY The side ai...

Page 2105: ...20 Side Airbag Sensor Assembly LH Seat Belt Pretensioner LH Side Airbag Assembly LH Squib Door Side Airbag Sensor LH RS 4 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG 2005 CELICA RM1131U 11 SRS CONNECTORS HINT SRS connectors are located as shown in the following illustra tion No Item Application 1 Terminal Twin Lock Mechanism Connectors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 Airbag Activ...

Page 2106: ...nctions and specifically designed for the SRS are used in the locations shown on the previous page to ensure high reliability These connectors use durable gold plated terminals 1 Terminal Twin Lock Mechanism Each connector has a two piece component con sisting of a housing and a spacer This design en ables the terminal to be locked securely by two lock ing devices the retainer and the lance to pre...

Page 2107: ...A RM1131U HINT The type of connector is shown in the diagram on the previous page 3 Electrical Connection Check Mechanism This mechanism electrically checks that connectors are connected correctly and completely The electri cal connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector hous ing lock is locked HINT The ill...

Page 2108: ...ultaneously When a deceleration force acts on the sensors 2 squibs in the driver airbag and front pas senger airbag ignite and generate gas The gas discharg ing into the driver airbag and front passenger airbag rap idly increases the pressure inside the bags breaking open the steering wheel pad and instrument panel Bag inflation then ends and the bags deflate as the gas is discharged through disch...

Page 2109: ...in them without rubbing b As they are fitted in the outer slides rearward Press it un til the outer returns to its original position again If fitting stops half way connectors will separate c Be sure to insert until they are locked After fitting in pull them slightly to check that they are locked When locked make sure that the outer returns to its original position and sound at the time of fitting...

Page 2110: ...lider Slider SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG RS 9 2005 CELICA RM1131U 14 DISCONNECTION OF SIDE AIRBAG CONNECTOR a Place a finger on the slider b Slide the slider to release lock c Disconnect the connector 15 CONNECTION OF SIDE AIRBAG CONNECTOR 2109 ...

Page 2111: ...g in pull them slightly to check that they are locked When locked make sure that the outer returns to its original position and sound at the time of fitting in can be heard HINT S As the slider slides do not touch it S Be careful not to deform the release board If the release board is deformed replace it with a new one 16 DISCONNECTION OF CONNECTORS FOR STEERING WHEEL PAD with AIRBAG AND FRONT PAS...

Page 2112: ... in the same direction as shown in the illustra tion fit in them without rubbing b Be sure to insert until they are locked After fitting in pull them slightly to check that they are locked When locked make sure that the outer returns to its original position and sound at the time of fitting in can be heard HINT S As the slider slides do not touch it S Be careful not to deform the release board If ...

Page 2113: ...Wheel Pad Column Lower Cover N m kgf cm ft lbf Specified torque 8 8 90 78 in lbf 34 350 25 8 8 90 78 in lbf Torx screw Torx screw RS 12 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 2005 CELICA RM1131U STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS 2112 ...

Page 2114: ...YSTEM STEERING WHEEL PAD AND SPIRAL CABLE RS 13 2005 CELICA RM1131U REMOVAL HINT For step 1 to 4 refer to page SR 13 1 REMOVE STEERING WHEEL PAD 2 REMOVE STEERING WHEEL 3 REMOVE UPPER AND LOWER COLUMN COVERS 4 REMOVE SPIRAL CABLE 2113 ...

Page 2115: ...Do a visual check which includes the following items with the steering wheel pad with airbag removed from the ve hicle S Check cuts minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion S Check cuts and cracks in wire harness and chip ping in connectors S Check the deformation of the horn button contact plate of the steering wheel CAUTION For remova...

Page 2116: ...on on the horn button contact plate of the steering wheel S Check the damage on the spiral cable connector and wire harness CAUTION For removal and installation of the steering wheel pad see page SR 13 and SR 21 and be sure to follow the correct procedure HINT S If the horn button contact plate of the steering wheel is de formed never repair it Always replace the steering wheel assembly with a new...

Page 2117: ...of doors and where it will not create a nuisance to nearby residents S When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise SST 09082 00700 S When deploying an airbag perform the operation at least 10 m 33 ft away from the steering wheel pad S The steering wheel pad is very hot when the airbag is deployed so ...

Page 2118: ...ctivation switch and check that the LED of the SST activation switch lights up CAUTION If the LED lights up when the activation switch is not being pressed SST malfunction is probable so definitely do not use the SST 3 Disconnect the SST from the battery b Install the SST CAUTION Check that there is no looseness in the steering wheel and steering wheel pad 1 While turning the steering wheel right ...

Page 2119: ...af ter deployment S Use gloves and safety glasses when handling a steer ing wheel pad with the deployed airbag S Always wash your hands with water after completing the operation S Do not apply water etc to a steering wheel pad with the deployed airbag S When scrapping a vehicle deploy the airbag and scrap the vehicle with the steering wheel pad still installed S When moving a vehicle for scrapping...

Page 2120: ...over d Using a service purpose wire harness tie down the steer ing wheel pad to the disc wheel Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more CAUTION If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad it may be snapped by the shock when the airbag is deployed This is highly dangerous Always use a wire harness for vehic...

Page 2121: ...ng wheel pad to the disc wheel through the hub nut holes Position the steering wheel pad con nector so that it hangs downward through a hub hole in the disc wheel CAUTION S Make sure that the wire harness is tight It is very dan gerous when looseness in the wire harness results in the steering wheel pad coming free due to the shock from the airbag deploying S Always tie down the steering wheel pad...

Page 2122: ...33 ft away from the steering wheel pad tied down on the disc wheel g Cover the steering wheel pad with a cardboard box or tires S Covering method using a cardboard box Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N 20 kg 44 lb Size of cardboard box Must exceed the following dimensions X 460 mm 18 11 in Y 650 mm 25 59 in NOTICE ...

Page 2123: ...inal 2 Check that no one is within 10 m 33 ft area around the disc wheel which the steering wheel pad is tied to 3 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up i Dispose of the steering wheel pad with airbag CAUTION S The steering wheel pad is very hot when the airbag is deployed so leave it alone f...

Page 2124: ...nt S When moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag use gloves and safety glasses S Use gloves and safety glasses when handling a steer ing wheel pad with deployed airbag S Always wash your hands with water after completing the operation S Do not apply water etc to a steering wheel pad with deployed airbag 1 Remove the steering wheel pad from the steeri...

Page 2125: ...d If the spiral cable has been found to be faulty in troubleshooting Spiral cable If the steering wheel pad has been found to be faulty during checking items See page RS 14 Steering wheel pad If the steering wheel has been found to be faulty during checking items See page RS 14 Steering wheel If the spiral cable has been found to be faulty during checking items See page RS 14 Spiral cable If the s...

Page 2126: ...M STEERING WHEEL PAD AND SPIRAL CABLE RS 25 2005 CELICA RM1131U INSTALLATION HINT For step 1 to 4 refer to page SR 21 1 INSTALL SPIRAL CABLE 2 INSTALL UPPER AND LOWER COLUMN COVERS 3 INSTALL STEERING WHEEL 4 INSTALL STEERING WHEEL PAD 2125 ...

Page 2127: ... cm ft lbf Specified torque Front Passenger Airbag Assembly 20 205 15 Lower Finish Panel RS 26 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY 2005 CELICA RM1131U FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS 2126 ...

Page 2128: ...R a Remove the 3 screws 2 bolts and lower finish panel b Remove the connector cover from the lower finish panel NOTICE When handling the airbag connector take care not to dam age the airbag wire harness c Disconnect the airbag connector 2 REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the bolt and 2 nuts CAUTION S Do not store the front passenger airbag assembly with the airbag deployment side faci...

Page 2129: ...SPECT SUPPLEMENTAL RESTRAINT SYSTEM a Do a diagnostic system check See page DI 884 b Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle S Check cuts minute cracks or marked discoloration on the front passenger airbag assembly S Check cuts and cracks in wire harness and for chip ping in connectors S Check the deformation or cracks ...

Page 2130: ...h the front passenger airbag assembly removed from the vehicle S Check the deformation or cracks on the instrument panel and instrument panel reinforcement S Check the damage on the connector and wire har ness CAUTION For removal and installation of the front passenger airbag assembly see page SR 13 and SR 21 and be sure to fol low the correct procedure HINT If the instrument panel or instrument p...

Page 2131: ...residents S When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the op eration in a place away from electrical noise SST 09082 00700 S When deploying an airbag perform the operation at least 10 m 33 ft away from the front passenger air bag assembly S The front passenger airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 m...

Page 2132: ...ag connector c Install the SST 1 Connect the connectors of the 2 SST to the front passenger airbag assembly connector SST 09082 00700 09082 00760 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 2 Move the SST to at least 10 m 33 ft away from the front of the vehicle 3 Close all the doors and windows of the vehicle NOTICE Take care not to ...

Page 2133: ...er airbag assembly with the deployed airbag use gloves and safety glasses HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up 2 DEPLOYMENT WHEN DISPOSING OF FRONT PAS SENGER AIRBAG ASSEMBLY ONLY NOTICE S When disposing of the front passenger airbag assem bly only never use the customer s vehicle to deploy the airbag S Be sure to follow the procedure given belo...

Page 2134: ...ied down with too thin wire harness it may snap This is highly danger ous Always use a wire harness which is at least 1 25 mm2 0 0019 in2 HINT To calculate the square of the stripped wire harness section Square 3 14 X Diameter 2 divided by 4 1 Install the 2 nuts on the front passenger airbag as sembly 2 Wind the wire harness around the bolts and pass the wire harness though the installation holes ...

Page 2135: ... disposing of the airbag use a redundant tire c Check functioning of the SST See step 1 a on page RS 16 SST 09082 00700 d Place the tires 1 Place at least 2 tires under the tire to which the front passenger airbag assembly is tied 2 Place at least 2 tires over the tire to which the front passenger airbag assembly is tied The top tire should have the wheel installed 3 Tie the tires together with 2 ...

Page 2136: ...T activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up g Dispose of the front passenger airbag assembly CAUTION S The front passenger airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment S Use gloves and safety glasses when handling a front passenger airbag as...

Page 2137: ...when handling a front passenger airbag assembly with the deployed airbag S Always wash your hands with water after completing the operation S Do not apply water etc to a front passenger airbag assembly with the deployed airbag 1 Remove the front passenger airbag assembly from the instrument panel See page RS 27 2 Place the front passenger airbag assembly in a vi nyl bag tie the end tightly and dis...

Page 2138: ...ont passenger airbag assembly If the front passenger airbag assembly has been found to be faulty during checking items See page RS 28 Front passenger airbag assembly If the instrument panel has been found to be faulty during checking items See page RS 28 Instrument panel If the instrument panel reinforcement has been found to be faulty during checking items See page RS 28 Instrument panel reinforc...

Page 2139: ...ger airbag assembly take care that the wiring does not interfere with other parts and is not pinched between other parts S Make sure that no foreign objects are trapped be tween the airbag bag and within the module NOTICE If the front passenger airbag assembly has been dropped or there are cracks dents or other defects in the case or connector replace the front passenger airbag assembly with a new...

Page 2140: ...Reclining Adjuster Knob Reclining Adjuster Release Handle Front Seat Cushion Shield z Hog Ring z Non reusable part 21 210 15 37 375 27 21 210 15 43 440 32 43 440 32 37 375 27 Inner Front Seat Cushion Shield 37 375 27 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG ASSEMBLY RS 39 2005 CELICA RM1131U SIDE AIRBAG ASSEMBLY COMPONENTS 2139 ...

Page 2141: ...d 4 bolts b Disconnect the side airbag connector NOTICE When handling the airbag connector take care not to dam age the airbag wire harness c Remove the front seat 2 REMOVE RECLINING ADJUSTER RELEASE HANDLE 3 REMOVE RECLINING ADJUSTER KNOB 4 REMOVE FRONT SEAT CUSHION SHIELD 5 REMOVE INNER FRONT SEAT CUSHION SHIELD Remove the screw and inner front seat cushion shield 6 REMOVE SEAT CUSHION ASSEMBLY ...

Page 2142: ...RS 41 2005 CELICA RM1131U 7 REMOVE SEATBACK ASSEMBLY a Remove the hog rings of the seatback frame as shown in the illustration b Remove the 4 bolts and seatback assembly CAUTION Do not store the seatback assembly with the airbag deploy ment side facing downward 2141 ...

Page 2143: ...bly removed from the vehicle S Check cuts and cracks of the side airbag assembly S Check cuts and cracks in wire harness and chip ping in connectors CAUTION For removal and installation of the seatback assembly see page RS 40 and RS 50 Be sure to follow the correct pro cedure 3 Vehicle involved in a collision and airbag is deployed INSPECT SUPPLEMENTAL RESTRAINT SYSTEM a Do a diagnostic system che...

Page 2144: ... to nearby residents S When deploying the airbag always use the specified SST SRS Airbag Deployment Tool perform the op eration in a place away from electrical noise SST 09082 00700 S When deploying an airbag perform the operation at least 10 m 33 ft away from the airbag assembly S The side airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after depl...

Page 2145: ...ICE Take care not to damage the SST wire harness 4 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal d Deploy the airbag 1 Check that no one is inside the vehicle or within 10 m 33 ft area around the vehicle 2 Press the SST activation switch and deploy the air bag CAUTION S The side airbag assembly is very hot when the airbag is deployed ...

Page 2146: ...ge RS 40 b Open the fastener of the seatback cover c Remove the side airbag assembly from the seatback as sembly CAUTION When storing the side airbag assembly keep the upper sur face of the airbag deployment side facing upward d Using a service purpose wire harness tie down the side airbag assembly to the tire Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more CAUTION I...

Page 2147: ...nside Tire size Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION S Make sure the wire harness is tight It is very danger ous when a loose wire harness results in the side air bag assembly coming free due to the shock from the airbag deploying S Always tie down the side airbag assembly with the airbag deployment side facing inside NOTICE The tire will...

Page 2148: ...of the 2 SST to the side airbag assembly connector SST 09082 00700 09082 00750 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock Also se cure some slack for the SST wire harness inside the tire h Deploy the airbag 1 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal 2 Check that no ...

Page 2149: ...ispose of the side airbag assembly CAUTION S The side airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment S Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag S Do not apply water etc to a side airbag assembly with the deployed airbag S Always wash your hands with water after completing the oper...

Page 2150: ...g assembly has been found to be faulty in troubleshooting Seatback assembly If the side airbag assembly has cuts during checking items See page RS 42 Seatback assembly If the side airbag assembly has been found to be faulty during checking items See page RS 42 Seatback assembly If the seatback assembly has been dropped Seatback assembly CAUTION For removal and installation of the seatback assembly...

Page 2151: ...s 1 INSTALL SEATBACK ASSEMBLY a Install the seatback assembly to the seat adjuster with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b Install 5 new hog rings HINT When installing the hog rings take care to prevent wrinkles as little as possible 2 INSTALL SEAT CUSHION ASSEMBLY a Install the seat cushion assembly with the 4 bolts Torque 21 N m 210 kgf cm 15 ft lbf b Install the wire harness to th...

Page 2152: ... the airbag wire harness a Connect the side airbag connector b Slide the front seat to the most front position NOTICE Make sure that seat adjuster locks c Without holding the seat track handle mount the seat to the vehicle HINT If holding the seat track handle the adjusted rearmost position slip off d Tighten the bolts on the front side temporarily from the bolt on the inner side tighten them comp...

Page 2153: ... Finish Panel RH End Finish Panel LH Finish Panel Upper Console Cover Console Box Hole Cover Console Box Lower No 1 Panel Lower Finish Panel 20 205 15 20 205 15 RS 52 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG SENSOR ASSEMBLY 2005 CELICA RM1131U AIRBAG SENSOR ASSEMBLY COMPONENTS 2152 ...

Page 2154: ... 8 refer to page BO 79 1 REMOVE LOWER FINISH PANEL 2 REMOVE LOWER NO 1 PANEL 3 REMOVE FINISH PANEL 4 REMOVE UPPER CONSOLE COVER 5 REMOVE CONSOLE BOX HOLE COVER 6 REMOVE CONSOLE BOX 7 REMOVE END FINISH PANEL LH 8 REMOVE END FINISH PANEL RH 9 REMOVE AIRBAG SENSOR ASSEMBLY a Disconnect the airbag sensor connectors NOTICE Disconnect the connectors with the airbag sensor assem bly installed b Using a t...

Page 2155: ...ON 1 VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 884 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page DI 884 3 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly See page DI 884 2154 ...

Page 2156: ...s replace the airbag sensor assembly S If the SRS has been deployed in a collision S If the airbag sensor assembly has been found to be faulty in troubleshooting S If the airbag sensor assembly has been dropped CAUTION For removal and installation of the airbag sensor assembly see page RS 53 and RS 56 Be sure to follow the correct procedure 2155 ...

Page 2157: ... b Connect the airbag sensor connectors NOTICE S Connection of the connector is done after the sensor assembly has been installed S Make sure the sensor assembly is installed with the specified torque S If the sensor assembly has been dropped or there are cracks dents or other defects in the case bracket or connector replace the sensor assembly with a new one S When installing the senor assembly t...

Page 2158: ...ner Hose Air Filter Air Cleaner Case Upper Front Fender Apron Seal Front Airbag Sensor RH Front Airbag Sensor LH Air Cleaner Cap 20 205 15 20 205 15 SUPPLEMENTAL RESTRAINT SYSTEM FRONT AIRBAG SENSOR RS 57 2005 CELICA RM1131U FRONT AIRBAG SENSOR COMPONENTS 2157 ...

Page 2159: ...S has deployed S Never repair a sensor in order to reuse it 1 LH REMOVE FRONT AIRBAG SENSOR a Remove the air cleaner hose b Remove the air cleaner cap c Remove the air filter d Remove the 2 bolts and air cleaner case e Disconnect the connector NOTICE Disconnect the connector with sensor assembly installed f Remove the 2 bolts and front airbag sensor LH 2 RH REMOVE FRONT AIRBAG SENSOR a Remove the ...

Page 2160: ... See page DI 884 b If the front fender of the car or its periphery is damaged do a visual check for damage to the front airbag sensor which includes the following items even if the airbag was not deployed S Check the bracket deformation S Check the paint peeling off the bracket S Check the cracks dents or chips in the case S Check the cracks dents chipping and scratches in the connector S Check th...

Page 2161: ...n a collision Replace both the left and right airbag sensors S If the front airbag sensor has been found to be faulty in troubleshooting S If the front airbag sensor has been found to be faulty during checking items See page RS 59 S If the front airbag sensor has been dropped CAUTION For removal and installation of the front airbag sensor see page RS 58 and RS 61 Be sure to follow the correct proc...

Page 2162: ...ckets or con nector replace the removed sensor with a new one S The front sensor is equipped with an electrical con nection check mechanism Be sure to lock this mech anism securely when connecting the connector If the connector is not securely locked a malfunction code will be detected by the diagnostic system HINT Install the front airbag sensor with the arrow on the sensor fac ing toward the fro...

Page 2163: ...t Cushion Assembly Deck Trim Side Panel Deck Trim Side Cover Rear Seatback Assembly RH Package Tray Trim Panel Deck Trim Rear Cover Rear Seatback Assembly LH 20 205 15 7 8 80 69 in lbf 18 185 13 Luggage Compartment Tray RS 62 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG SENSOR ASSEMBLY 2005 CELICA RM1131U SIDE AIRBAG SENSOR ASSEMBLY COMPONENTS 2162 ...

Page 2164: ... may be de stroyed by static electricity HINT For step 1 to 9 refer to page BO 88 1 REMOVE PACKAGE TRAY TRIM PANEL 2 REMOVE REAR SEATBACK ASSEMBLY LH AND RH 3 REMOVE REAR SEAT CUSHION ASSEMBLY 4 REMOVE DECK TRIM REAR COVER 5 REMOVE DECK TRIM SIDE COVER 6 REMOVE DECK TRIM SIDE PANEL 7 REMOVE LUGGAGE COMPARTMENT TRAY 8 REMOVE REAR SEATBACK HINGE 9 REMOVE QUARTER TRIM PANEL 10 REMOVE SIDE AIRBAG SENS...

Page 2165: ...N 1 VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 884 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page DI 884 3 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly See page DI 884 2164 ...

Page 2166: ...de airbag sensor assembly S If the side airbag assembly has been deployed in a collision S If the side airbag sensor assembly has been found to be faulty in troubleshooting S If the side airbag sensor assembly has been dropped CAUTION For removal and installation of the side airbag sensor assembly see page RS 63 and RS 66 Be sure to follow the correct procedure 2165 ...

Page 2167: ...he sensor assembly is installed with the specified torque S If the sensor assembly has been dropped or there are cracks dents or other defects in the case bracket or connector replace the sensor assembly with a new one S When installing the sensor assembly take care that the SRS wiring does not interfere with other parts and is not pinched between other parts S After installation shake the sensor ...

Page 2168: ...e Airbag Sensor Front Door Lower Frame Bracket Garnish No 2 Door Inside Handle Bezel Outer Mirror Switch Assembly Door Trim 8 0 82 71 in lbf SUPPLEMENTAL RESTRAINT SYSTEM DOOR SIDE AIRBAG SENSOR RS 67 2005 CELICA RM1131U DOOR SIDE AIRBAG SENSOR COMPONENTS 2167 ...

Page 2169: ...w parts S Never reuse the sensor involved in a collision when the SRS has deployed S Never repair a sensor in order to reuse it HINT For step 1 to 4 refer to page BO 11 1 REMOVE NO 2 DOOR INSIDE HANDLE BEZEL 2 REMOVE OUTER MIRROR SWITCH ASSEMBLY 3 REMOVE FRONT DOOR LOWER FRAME BRACKET GARNISH 4 REMOVE DOOR TRIM 5 REMOVE DOOR SIDE AIRBAG SENSOR a Disconnect the door side airbag sensor connector NOT...

Page 2170: ...m check See page DI 884 b If the front door or its periphery is damaged do a visual check for damage to the door side airbag sensor which includes the following items even if the airbag was not deployed S Check the bracket deformation S Check the paint peeling off the bracket S Check the cracks dents or chips in the case S Check the cracks dents chipping and scratches in the connector S Check the ...

Page 2171: ...sembly has been deployed in a collision S If the door side airbag sensor has been found to be faulty in troubleshooting S If the door side airbag sensor has been found to be faulty during checking items See page RS 59 S If the door side airbag sensor has been dropped CAUTION For removal and installation of the door side airbag sensor see page RS 68 and RS 71 Be sure to follow the correct procedure...

Page 2172: ...e cracks dents or other defects in the case brackets or con nector replace the removed sensor with new one S The door side airbag sensor is equipped with an elec trical connection check mechanism Be sure to lock this mechanism securely when connecting the con nector If the connector is not securely locked a mal function code will be detected by the diagnostic sys tem HINT Install the door side air...

Page 2173: ...ination Meter Warning Light Front Airbag Sensor LH Front Airbag Sensor RH Seat Belt Pretensioner RH Seat Belt Pretensioner LH Side Airbag Sensor Assembly LH Airbag Sensor Assembly Door Side Airbag Sensor LH Side Airbag Assembly LH Spiral Cable RS 72 SUPPLEMENTAL RESTRAINT SYSTEM WIRE HARNESS AND CONNECTOR 2005 CELICA RM1131U WIRE HARNESS AND CONNECTOR LOCATION 2172 ...

Page 2174: ...assembly All the connectors in the system are a standard yellow color 1 VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 884 2 VEHICLES INVOLVED IN COLLISION a Do a diagnostic system check See page DI 884 b Check breaks in all wires of the SRS wire harness and exposed conductors c Check to see if the SRS wire harness connectors are cracked or chipped 2173 ...

Page 2175: ... harness or connector S If any part of the SRS wire harness or any connector has been found to be faulty in troubleshoot ing S If any part of the SRS wire harness or any connector has been found to be faulty during checking items See page RS 73 CAUTION If the wire harness used in the SRS is damaged replace the whole wire harness assembly 2174 ...

Page 2176: ...on the discharge headlight using another power source except vehicle s 2 HEADLIGHT BULB REPLACEMENT a If the adhered oil is left on the halogen lamp surface the lamp service life is shortened as it becomes hot when it is turned on b Since the internal pressure of a discharge headlight and halogen bulbs is high dropping hitting or damaging the bulb may cause the glass to scatter Therefore handle th...

Page 2177: ...m 4 Wire Harness BE 18 BE 18 DI 1117 Lo Beam does not come on One side 1 HEAD LH LWR Fuse 2 HEAD RH LWR Fuse 3 Headlight Bulb 4 Wire Harness BE 10 BE 10 Hi Beams do not come on Both sides 1 DRL NO 2 DIMMER Relay 2 MAIN Fuse 3 HEAD LVL DRL NO 1 Fuse 4 Headlight Dimmer Switch 5 Body Control System 6 Wire Harness BE 18 BE 10 BE 24 BE 18 DI 1117 Hi Beam does not come on ONE SIDE 1 HEAD LH UPR Fuse 2 H...

Page 2178: ...mer Switch 4 Light Control Switch 5 Body Control System 6 Headlight Bulb 7 HEAD RH UPR or HEAD LH UPR Fuse 8 Wire Harness BE 18 BE 18 BE 18 BE 18 DI 1117 BE 10 Lo Beam and Hi Beam of both sides do not come on Taillights do come on neither 1 Light Control Switch 2 Body Control System 3 Wire Harness BE 18 DI 1117 Lo Beam and Hi Beam of only one side do not come on 1 HEAD RH LWR and HEAD RH UPR Fuse ...

Page 2179: ...use 2 Wire Harness BE 10 Hazard warning light does not come on in one direction 1 Hazard Warning Switch 2 Wire Harness BE 30 Turn signal does not come on Combination meter wiper and washer do not operate 1 Ignition Switch 2 TURN Fuse 3 Turn Signal Switch 4 Wire Harness BE 15 BE 10 BE 30 Turn signal does not come on Combination meter wiper and washer are normal 1 TURN Fuse 2 Turn Signal Switch 3 Wi...

Page 2180: ...ome on 1 Bulb 2 Wire Harness STOP LIGHT SYSTEM Symptom Suspect Area See page Stop lights do not come on 1 STOP Fuse 2 Stop Light Switch 3 Bulb 4 Wire Harness BE 10 BE 37 Stop lights remain ON 1 Stop Light Switch 2 Wire Harness BE 37 Only one light does not come on 1 Bulb 2 Wire Harness WIPER AND WASHER SYSTEM Symptom Suspect Area See page Wipers and washers do not operate 1 WIPER Fuse and WASHER F...

Page 2181: ...Temperature Receiver Gauge 2 Engine Coolant Temperature Sender Gauge 3 Meter Circuit 4 Wire Harness BE 50 BE 50 BE 46 All illumination lights do not come on 1 TAIL Fuse I P J B 2 Light Control Rheostat 3 Meter Circuit 4 Wire Harness BE 10 BE 50 BE 46 Only one illumination light does not come on 1 LED 2 Meter Circuit BE 46 Warning Lights COMBINATION METER Symptom Suspect Area See page Warning light...

Page 2182: ...alfunction indicator light does not come on 1 LED 2 ECM 3 Wire Harness DI 1 A T shift position indicator light does not come on 1 LED or LCD 2 Park Neutral Position Switch 3 Light Control Rheostat 4 Meter Circuit 5 Wire Harness DI 701 DI 789 BE 50 BE 46 O D OFF indicator light does not come on 1 LED or LCD 2 O D Main Switch 3 ECM 4 Meter Circuit 5 Wire Harness DI 746 DI 829 DI 1 BE 46 Turn indicat...

Page 2183: ...t operate 1 Power Window Master Switch BE 62 Only one window glass does not move 1 Power Window Master Switch 2 Power Window Motor 3 Wire Harness BE 62 BE 62 Window lock system does not operate 1 Power Window Master Switch BE 62 Illumination does not come on 1 Power Window Master Switch BE 62 POWER DOOR LOCK CONTROL SYSTEM Symptom Suspect Area See page Door lock control system does not operate ALL...

Page 2184: ...r Lock Receiver 3 Body ECU 4 Wire Harness BE 66 BE 66 DI 1117 Wireless door lock operates but the buzzer does not sound The buzzer does not sound when the customize function prohib its 1 Wireless Door Lock Buzzer 2 Wireless Door Lock Receiver 3 Wire Harness BE 66 SLIDING ROOF SYSTEM Symptom Suspect Area See page Sliding roof system does not operate 1 S ROOF Fuse I P J B 2 TENS RDC Fuse I P J B 3 S...

Page 2185: ...BE2FH 03 I13313 Engine Room Junction Block Engine Room Relay Block No 2 Instrument Panel Junction Block BE 10 BODY ELECTRICAL POWER SOURCE 2005 CELICA RM1131U POWER SOURCE LOCATION 2184 ...

Page 2186: ... DCC 26 ALT S 27 SPARE RELAYS A FAN NO 2 Relay B FAN NO 1 Relay C Circuit Opening Relay D Horn Relay E FAN NO 3 Relay F Magnetic Clutch Relay G IG2 Relay H EFI Relay I Headlight Control Relay 120 A 30 A 50 A 30 A 15 A 20 A 15 A 50 A 25 A 7 5 A 10 A 15 A 10 A 15 A 30 A 40 A 15 A 7 5 A 10 A 10 A 10 A 10 A 7 5 A 20 A 25 A 7 5 A 7 5 A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 23 25 2...

Page 2187: ...22 MULTI FUSE 23 DEF 15 A 15 A 25 A 20 A 20 A 10 A 15 A 7 5 A 7 5 A 15 A 25 A 15 A 7 5 A 10 A 10 A 20 A 10 A 5 A ABS IG WARNING FAN RLY ECU IG 7 5 A DOME MPX B ECU B 5 A BODY ECU IG BK UP LP TENS RDC DEF RLY 7 5 A ECU ACC PANEL2 PANEL1 30 A RELAYS A B IG1 Relay C Defogger Relay D Taillight Control Relay 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 A B C D 16 BE 12 BODY ELECTRICAL POWER...

Page 2188: ...OOM RELAY BLOCK NO 2 1 2 3 4 5 1 2 3 5 1 2 3 5 FUSES 1 HEAD LH UPR 10A 2 HEAD RH UPR 10A RELAYS A DRL No 4 Relay B DRL No 3 Relay C DRL No 2 Relay A B C 1 2 BODY ELECTRICAL POWER SOURCE BE 13 2005 CELICA RM1131U 2187 ...

Page 2189: ... Switch D Key Unlock Warning Switch Instrument Panel Junction Block D Body ECU BE 14 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 2005 CELICA RM1131U IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH LOCATION 2188 ...

Page 2190: ... Continuity ON 1 2 3 5 6 Continuity START 1 2 4 5 6 Continuity If continuity is not as specified replace the switch 2 INSPECT KEY UNLOCK WARNING SWITCH CONTI NUITY Switch position Tester connection Specified condition OFF Key removed No continuity ON Key set 1 2 Continuity If continuity is not as specified replace the switch 3 INSPECT KEY UNLOCK WARNING BUZZER Check that the buzzer sounds when dri...

Page 2191: ...t Dimmer Switch Ignition Switch Headlights Automatic Light Control Sensor Taillights Instrument Panel Junction Block D Body ECU D TAIL Fuse D TAIL Relay Engine Room R B No 2 D DRL NO 2 DIMMER Relay D DRL NO 3 Relay D DRL NO 4 Relay D HEAD LH UPR Fuse D HEAD RH UPR Fuse D Light Control Computer BE 16 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 2005 CELICA RM1131U HEADLIGHT AND TAILLIGHT SYSTEM LO...

Page 2192: ...ombination Switch D Light Control Switch D Headlight Dimmer Switch Combination Switch D Wiper and Washer Switch Spiral Cable N16821 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 17 2005 CELICA RM1131U COMPONENTS 2191 ...

Page 2193: ...Continuity Flash 7 8 16 Continuity If continuity is not as specified replace the switch 3 INSPECT HEAD RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 4 INSPECT DAYTIME RUNNING LIGHT NO 2 DIMMER RELAY CONTINUITY Condition Tester connection Specified conditio...

Page 2194: ...relay 8 w Automatic light control system INSPECT AUTOMATIC LIGHT CONTROL a Turn the ignition switch to ON b Turn the light control switch to AUTO c Gradually cover the top of the sensor d Verify that the accessory lights and the headlights comes on Daytime running light ON 9 w Automatic light control system INSPECT AUTOMATIC LIGHT CONTROL a Gradually expose the sensor b Verify that the headlights ...

Page 2195: ... ON 5 2 9 0 V If circuit is as specified perform the inspection on the following page If the circuit is not as specified inspect the circuit connected to other parts b Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side HINT S Ignition switch ON S Light control switch OFF S Vehicle s surroundings are bright Tester connection Condition Sp...

Page 2196: ...ting of the headlight stops and the condition is maintained until power is turned ON again headlight dimmer switch OFF ON High lamp voltage Lighting of the headlight stops and the condition is maintained until power is turned ON again headlight dimmer switch OFF ON Bulb flushing S The condition is maintained more than 60 seconds S Lighting of the headlight stops and the condition is maintained unt...

Page 2197: ...BE1CY 16 I13678 For Adjustment in Vertical Direction BE 22 BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM 2005 CELICA RM1131U ADJUSTMENT 2196 ...

Page 2198: ...a 90 degree angle as shown in the illustration 4 Draw a horizontal line H line on the paper showing where the headlights should strike 5 Draw a vertical line V line to where the center line of the vehicle is to be 6 Draw 2 vertical lines to where the both headlights should strike V RH and V LH lines 7 Draw a horizontal line by connecting the both low beam center marks to where the headlights shoul...

Page 2199: ...Block D HEAD LVL Fuse Headlight Beam Level Control Actuator Headlight Beam Level Control Switch Ignition Switch BE 24 BODY ELECTRICAL HEADLIGHT BEAM LEVEL CONTROL SYSTEM 2005 CELICA RM1131U HEADLIGHT BEAM LEVEL CONTROL SYSTEM LOCATION 2198 ...

Page 2200: ...ified replace the switch 2 INSPECT HEADLIGHT BEAM LEVEL CONTROL SWITCH ILLUMINATION Connect the battery positive lead to terminal 3 and the bat tery negative lead to terminal 6 and check that the illumina tion light comes on If operation is not as specified replace the switch 3 INSPECT HEADLIGHT BEAM LEVEL CONTROL AC TUATOR OPERATION NOTICE If a resister is not placed switch may be damaged Disconn...

Page 2201: ...Fog Lights Combination Switch D Fog Light Switch Instrument Panel Junction Block D Body ECU D FR FOG Fuse Front Fog Light Relay BE 26 BODY ELECTRICAL FOG LIGHT SYSTEM 2005 CELICA RM1131U FOG LIGHT SYSTEM LOCATION 2200 ...

Page 2202: ... Switch position Tester connection Specified condition OFF No continuity ON 10 11 Continuity If continuity is not as specified replace the switch 2 INSPECT FRONT FOG LIGHT RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 2201 ...

Page 2203: ...BE0OX 04 I25696 A bolt BE 28 BODY ELECTRICAL FOG LIGHT SYSTEM 2005 CELICA RM1131U ADJUSTMENT ADJUST FOG LIGHT AIM A bolt Vertical Direction 2202 ...

Page 2204: ...h D Turn Signal Switch Instrument Panel Junction Block D TURN Fuse Turn Signal Lights Engine Room Junction Block D HAZ Fuse Turn Signal Flasher BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM BE 29 2005 CELICA RM1131U TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION 2203 ...

Page 2205: ...n Specified condition OFF 5 7 Continuity ON 5 6 1 2 4 Continuity Illumination circuit 8 9 Continuity If continuity is not as specified replace the switch 3 INSPECT TURN SIGNAL FLASHER OPERATION a Connect the battery positive lead to terminal 2 and the battery negative lead to terminal 3 b Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3 then check that the bulbs fl...

Page 2206: ...ight Door Courtesy Switch Door Courtesy Switch Luggage Compartment Light Instrument Panel Junction Block D Body ECU D MULTI DOME Fuse BODY ELECTRICAL INTERIOR LIGHT SYSTEM BE 31 2005 CELICA RM1131U INTERIOR LIGHT SYSTEM LOCATION 2205 ...

Page 2207: ...rminals If continuity is not as specified replace the front personal light assembly or the bulb 3 INSPECT REAR ROOM LIGHT CONTINUITY a Disconnect the connector from the room light b Turn the room light switch to ON check that there is a con tinuity between terminal 1 and 2 If continuity is not as specified replace the light assembly or the bulb 4 INSPECT DOOR COURTESY SWITCH CONTINUITY a Check tha...

Page 2208: ...IOR LIGHT SYSTEM BE 33 2005 CELICA RM1131U 5 INSPECT LICENCE PLATE LIGHT CONTINUITY Using an ohmmeter check that there is a continuity between terminals If continuity is not as specified replace the light assembly or the bulb 2207 ...

Page 2209: ...BE0P2 17 I25690 Instrument Panel Junction Block D MULTI BK UP LP Fuse Back Up Lights BE 34 BODY ELECTRICAL BACK UP LIGHT SYSTEM 2005 CELICA RM1131U BACK UP LIGHT SYSTEM LOCATION 2208 ...

Page 2210: ... INSPECTION 1 M X INSPECT BACK UP LIGHT SWITCH CONTINUITY Switch position Tester connection Specified condition Free 1 2 No continuity Push 1 2 Continuity If continuity is not as specified replace the switch 2 A X INSPECT PARK NEUTRAL POSITION SWITCH CON TINUITY See page DI 701 or DI 789 2209 ...

Page 2211: ...0P4 14 I25689 Stop Light Switch Instrument Panel Junction Block D STOP Fuse High Mounted Stop Light Stop Lights BE 36 BODY ELECTRICAL STOP LIGHT SYSTEM 2005 CELICA RM1131U STOP LIGHT SYSTEM LOCATION 2210 ...

Page 2212: ...stem Switch position Tester connection Specified condition Switch pin pushed in Pedal released No continuity Switch pin free Pedal depressed 1 2 Continuity If continuity is not as specified replace the switch w cruise control system Switch position Tester connection Specified condition Switch pin pushed in Pedal released No continuity Switch pin free Pedal depressed 1 2 Continuity If continuity is...

Page 2213: ...R Fuse D WASHER Fuse Washer Tank D Washer Motor Front Wiper Motor and Link Combination Switch D Wiper and Washer Switch Rear Wiper Motor Ignition Switch BE 38 BODY ELECTRICAL WIPER AND WASHER SYSTEM 2005 CELICA RM1131U WIPER AND WASHER SYSTEM LOCATION 2212 ...

Page 2214: ...y Washer ON 2 11 Continuity If continuity is not as specified replace the switch 2 INSPECT FRONT WIPER INTERMITTENT OPERA TION a Turn the wiper switch to the INT position b Turn the intermittent time control switch to FAST position c Connect the battery positive lead to terminal 16 and the battery negative lead to terminal 2 d Connect the voltmeter positive lead to terminal 7 and the voltmeter neg...

Page 2215: ...tch and check that the voltage changes as shown in the table If operation is not as specified replace the wiper and washer switch 4 INSPECT REAR WIPER AND WASHER SWITCH CON TINUITY Switch position Tester connection Specified condition Washer 1 2 12 Continuity OFF No continuity INT 2 13 Continuity ON 2 10 Continuity Washer 2 2 10 12 Continuity If continuity is not as specified replace the switch 5 ...

Page 2216: ...tery positive lead to terminal 2 and bat tery negative lead to terminal 4 then check that the motor stops running at the stop position after the motor operates again If operation is not as specified replace the motor 8 Intermittent INSPECT REAR WIPER MOTOR AND RELAY OPERA TION Connect the battery positive lead to terminal 1 and the bat tery negative lead to terminal 2 and the motor body then check...

Page 2217: ...t be performed quickly within 20 seconds to prevent the coil from burning out If operation is not as specified replace the motor with a new one 11 w Rear wiper INSPECT REAR WASHER MOTOR OPERATION Connect the battery positive lead to terminal 2 and the bat tery negative lead to terminal 3 then check that the motor operates NOTICE These tests must be performed quickly within 20 seconds to prevent th...

Page 2218: ...ter D Meter Circuit Clock Assembly D Passenger Seat Belt Warning Light Occupant Detection Sensor Light Control Rheostat Ignition Switch Seat Belt Buckle Switch Parking Brake Switch Instrument Panel Junction Block D Body ECU D MULTI ECU B Fuse D MULTI WARNING Fuse D SRS IG Fuse D TAIL Fuse BODY ELECTRICAL COMBINATION METER BE 43 2005 CELICA RM1131U COMBINATION METER LOCATION 2217 ...

Page 2219: ...I13605 Door Courtesy Switches Fuel Sender Gauge BE 44 BODY ELECTRICAL COMBINATION METER 2005 CELICA RM1131U 2218 ...

Page 2220: ...I11735 Connector A Connector B BODY ELECTRICAL COMBINATION METER BE 45 2005 CELICA RM1131U 2219 ...

Page 2221: ...3 B7 A15 A19 Illumination B12 B4 B6 A12 B18 B3 B1 A11 A22 A9 B2 A13 B9 A4 B16 A2 A14 Buzzer ABS Discharge Low Oil PKB 1 2 3 4 M A T Oil Temp Open door Seat belt Fuel level MIL SRS Hi Beam HEAD TAIL TURN L TURN R CRUISE S Speedometer T Tachometer BE 46 BODY ELECTRICAL COMBINATION METER 2005 CELICA RM1131U CIRCUIT 2220 ...

Page 2222: ...Light control rheostat Evaporator temp sensor Ground Ground 9 Speed control unit Ground 2 3 4 5 6 7 8 10 11 12 13 14 15 9 1 16 17 18 Generator Clock Passenger seat belt warning Body ECU TAIL Fuse A C ECU ECM Tacho signal ECM ABS ECU Parking brake switch signal Turn signal switch Right side A C control panel A C switch indicator ABS ECU Automatic light control sensor O D off switch Front defogger s...

Page 2223: ...BE1D2 04 I11729 Meter Cover Circuit Plate Character Plate Meter Plate Meter Glass BE 48 BODY ELECTRICAL COMBINATION METER 2005 CELICA RM1131U COMPONENTS 2222 ...

Page 2224: ...MBINATION METER BE 49 2005 CELICA RM1131U DISASSEMBLY COMBINATION METER COVER a Remove the 8 screws b Remove the combination meter cover c Remove the meter circuit plate d Remove the 6 clips and the meter glass e Remove the 4 clips and the meter plate 2223 ...

Page 2225: ...minals with fixing pointer to the stopper Tester connection Resistance Ω A B 250 C D 250 If resistance value is not as specified replace the meter 3 INSPECT VEHICLE SPEED SENSOR OPERATION a Connect the battery positive lead to terminal 1 and the battery negative lead to terminal 2 b Connect the tester positive lead to terminal 3 and the tester negative lead to terminal 2 c Rotate the shaft d Check...

Page 2226: ...er 5 INSPECT TACHOMETER RESISTANCE Measure the resistance between terminals with fixing the point er to the stopper Tester connection Resistance Ω A B 250 C D 250 If resistance value is not as specified replace the meter 6 INSPECT FUEL RECEIVER GAUGE OPERATION a Disconnect the connector from the sender gauge assem bly b Turn the ignition switch ON check that the receiver gauge needle indicates EMP...

Page 2227: ...R GAUGE OPERATION a Disconnect the connector from the sender gauge b Turn the ignition switch ON then check that the receiver gauge needle indicates COOL c Ground the terminal of the wire harness side connector through a 3 4 W test bulb d Turn the ignition switch ON check that the bulb lights up and the receiver gauge needle moves toward the hot side If operation is not as specified inspect the se...

Page 2228: ...ng HINT Oil pressure should be over 24 5 kPa 0 25 kgf cm2 3 55 psi If operation is not as specified replace the switch 12 INSPECT BRAKE WARNING SYSTEM LIGHT a Disconnect the connector from the brake fluid level warn ing switch b Connect terminals on the wire harness side of the level warning switch connector c Start the engine then check that the brake warning light comes on If the warning light d...

Page 2229: ... switch ON switch pin released b Check that there is no continuity between terminal and switch body with the switch OFF switch pin pushed in If operation is not as specified replace the switch or inspect ground point 16 INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch and the ground terminal 1 of the wire harness side connector and check that the warning light...

Page 2230: ...witch Tension Reducer Solenoid in Retractor Assembly Instrument Panel Junction Block D MULTI TENS RDC Fuse BODY ELECTRICAL ELECTRIC TENSION REDUCER SYSTEM BE 55 2005 CELICA RM1131U ELECTRIC TENSION REDUCER SYSTEM LOCATION 2229 ...

Page 2231: ...c Disconnect the lead from the battery d Pull the belt upward and check that the belt is retracted quicker than in b when released HINT Do not tilt the retractor If the operation is not as specified replace the front seat outer belt assembly 2 INSPECT BUCKLE SWITCH CONTINUITY a Check that there is a continuity between terminals of the switch side connector with the switch ON belt fastened b Check ...

Page 2232: ...ent Panel Junction Block D MULTI DEF RLY Fuse D DEF Relay D DEF Fuse Defogger Wire Ignition Switch Heater Control Panel D Defogger Switch BODY ELECTRICAL DEFOGGER SYSTEM BE 57 2005 CELICA RM1131U DEFOGGER SYSTEM LOCATION 2231 ...

Page 2233: ...d check that the indicator light and the test bulb light for 12 to 18 minutes and go off afterward If operation is not as specified replace the switch 2 Connector disconnected INSPECT DEFOGGER SWITCH CIRCUIT Disconnect the connector from the switch and inspect the con nector on wire harness side as shown in the chart Tester connection Condition Specified condition 3 Ground Constant Continuity 5 Gr...

Page 2234: ... the circuit connected to other parts 4 INSPECT DEFOGGER RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 5 INSPECT DEFOGGER WIRE NOTICE S When cleaning the glass use a soft dry cloth and wipe the glass between the wires Take care not to damage the wires S Do...

Page 2235: ...e the voltmeter positive lead against the defogger positive terminal e Place the voltmeter negative lead with the foil strip against the heat wire at the positive terminal end and slide it toward the negative terminal end f The point where the voltmeter deflects from zero to sever al V is the place where the heat wire is broken HINT If the heat wire is not broken the voltmeter indicates 0 V at the...

Page 2236: ...ment Panel Junction Block D Body ECU D PWR No 1 Fuse D PWR No 2 Fuse Power Window Master Switch Ignition Switch Window Lock Switch BODY ELECTRICAL POWER WINDOW CONTROL SYSTEM BE 61 2005 CELICA RM1131U POWER WINDOW CONTROL SYSTEM LOCATION 2235 ...

Page 2237: ... Continuity OFF 1 17 10 17 Continuity DOWN 10 11 1 17 Continuity Passenger s switch Window lock Switch position Tester connection Specified condition UP 1 11 Continuity OFF 1 10 Continuity DOWN 10 11 Continuity If continuity is not as specified replace the switch 2 INSPECT POWER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals ...

Page 2238: ...Driver s door INSPECT PTC OPERATION a Disconnect the connector from the window motor b Connect the ammeter positive lead to terminal 1 of the wire harness side connector and the negative lead to ammeter negative terminal of the battery c Connect the battery positive lead to terminal 2 of the wire harness side connector and raise the window to the fully closed position d Continue to apply voltage a...

Page 2239: ...y c Connect the positive lead from the battery to terminal 2 of the wire harness side connector and raise the win dow to the fully closed position d Continue to apply voltage and check that the current changes from approximately 14 A to less than 1 A within 4 to 90 seconds e Disconnect the leads from terminals f Approximately 90 seconds later connect the battery posi tive lead to terminal 1 and th...

Page 2240: ... Junction Block D Body ECU D DOOR Fuse Door Lock Assembly D Door Lock Motor D Door Unlock Detection Switch Door Courtesy Switches Ignition Switch Back Door Lock Motor BODY ELECTRICAL POWER DOOR LOCK CONTROL SYSTEM BE 65 2005 CELICA RM1131U POWER DOOR LOCK CONTROL SYSTEM LOCATION 2239 ...

Page 2241: ...NUITY Switch position Tester connection Specified condition LOCK 3 5 Continuity OFF No continuity UNLOCK 3 6 Continuity If continuity is not as specified replace the switch 3 Passenger s door INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK 2 4 Continuity OFF No continuity UNLOCK 1 4 Continuity If continuity is not as specified replace t...

Page 2242: ...TOR OPERATION a Connect the battery positive lead to terminal 1 and the battery negative lead to terminal 2 and check that the door lock link moves to UNLOCK position b Reverse the polarity and check that the door lock link moves to LOCK position If operation is not as specified replace the door lock assembly 7 Passenger s door INSPECT DOOR LOCK MOTOR OPERATION a Connect the battery positive lead ...

Page 2243: ...assembly 9 INSPECT PASSENGER S DOOR PTC THERMISTOR OPERATION a Connect the battery negative lead to terminal 6 b Connect the ammeter positive lead to terminal 5 and the ammeter negative lead to the battery negative terminal and check that the current changes from approximately 3 2 A to less than 0 5 A within 20 to 70 se conds c Disconnect the leads from terminals d Approximately 60 seconds later c...

Page 2244: ... lead to terminal 6 b Attach a current measuring probe to either the positive lead or the negative lead and check that the cur rent changes from approximately 3 2 A to less than 0 5 A within 20 to 70 seconds c Disconnect the leads from terminals d Approximately 60 seconds later reverse the polarity and check that the door lock moves to the LOCK position If operation is not as specified replace the...

Page 2245: ...ck Motor D Door Unlock Detection Switch Ignition Switch D Key Unlock Warning Switch Door Courtesy Switches Instrument Panel Junction Block D Body ECU Back Door Lock Motor BE 70 BODY ELECTRICAL WIRELESS DOOR LOCK CONTROL SYSTEM 2005 CELICA RM1131U WIRELESS DOOR LOCK CONTROL SYSTEM LOCATION 2244 ...

Page 2246: ...tion 1 Keep about 1 M away from the outside handle of a driver s seat in the right direction 2 Face the transmitter toward the vehicle and press one of transmitter switches for about 1 sec Normal Reference D Operative distance may differ depending on the operator the way of holding the transmitter or its position D As the transmitter uses weak wave its operat ing range becomes narrowed when the we...

Page 2247: ...nition key cylinder and then pull it out then insert it again and turn the ignition switch OFF ON OFF once within 5 seconds after pulling out 2 After completing the procedure within 30 seconds turn the ignition switch OFF ON OFF 9 times HINT In the case that either of 1 and 2 conditions is not satisfied transfer to normal mode Reference When completing self diagnostic mode turn the ignition switch...

Page 2248: ...eived normal wave of UNLOCK switch 3 Received normal wave of PANIC switch 4 Compatibility of the recognition code or out from synchronization of rolling code OFF ON OFF ON OFF ON OFF ON 0 2 sec 0 5 sec 0 2 sec 0 2 sec 0 5 sec 0 5 sec 0 5 sec Transmitter faulty or wireless door lock re ceiver faulty Reference D Use another normal transmitter and check with the diagnostic mode and if the check resul...

Page 2249: ...stem faulty Transmitter and receiver are normal Yes No Wireless door control receiver check Yes Wire harness faulty short circuit Yes RDA terminal open circuit No Check RDA terminal circuit Check that the voltage of RDA is about 6 7 V when the transmitter is ON No When pressing each switch of the new or normal transmitter used in the same type vehicle check that all taillights chirps in the same w...

Page 2250: ...ere is constantly 10 to 14 V voltage at the connector terminal 5 B of the wireless door control receiver No Wire harness faulty Body ground open and contact error Yes Body ground check Check that continuity exists between the connector terminal 1 GND of the wireless door control receiver and body ground No Wireless door control receiver faulty 2249 ...

Page 2251: ...side terminal and battery to the bottom terminal then apply 3 V voltage to the transmitter d In the location approx 1 M away from driver s outside handle in the right direction check the transmitter opera tion as pressing transmission switch on the surface of the transmitter body Standard Remote control of the vehicle door lock can be operated HINT S The minimum operation distance differs dependin...

Page 2252: ...tery lithium battery from the transmitter c Connect the lead to the terminal of the transmitter and install the battery d Connect tester to the battery lithium battery and tester to the lead respectively e Press one of the transmitting switches on the transmitter for approx 1 second f Press the transmitting switch on the transmitter again to check the voltage Standard 2 1 V or more HINT S When the...

Page 2253: ... wire harness side as shown below Tester connection Condition Specified condition 1 Ground Always Continuity 5 Ground Always Battery voltage If the circuit is not as specified inspect the circuit connected to other parts b Connect the wire harness side connector to the receiver and inspect the wire harness side connector from the back side as shown below Tester connection Condition Specified condi...

Page 2254: ...y HINT Push the cover with fingers as shown in the illustration to make a chink and then pry out the cover from that chink using a screwdriver b Remove the transmitter c Remove the battery lithium battery NOTICE S Do not push the terminals with fingers S If prying up the battery lithium battery forcibly to re move the terminals are deformed d Install a battery lithium battery as shown in the illus...

Page 2255: ...er of registered codes exceeds 4 codes previously regis tered codes are erased in order starting from the first reg istered code S The rewrite mode is used to erase all previously regis tered codes and register only new recognition codes S The prohibition mode is used to erase all registered codes and cancels the wireless door lock function Use this mode when the transmitter is lost S The confirma...

Page 2256: ... CLOSED D Driver s door is UNLOCKED Insert the key into the ignition key cylinder then pull it out Repeat this twice within 5 seconds Open and close the door manual operation 2 times 1st time 2nd time OPEN CLOSE Close the all door and insert the key into the ignition key cylinder Within 40 secs Within 40 secs Insert the key into the ignition key cylinder then pull it out 1st time 2nd time OPEN CLO...

Page 2257: ...r that either the add mode or rewrite mode has been selected LOCK UNLOCK occurs once LOCK UNLOCK occurs twice Indicates that add mode has been selected Indicates that rewrite mode has been selected 1 sec LOCK 1 sec 1 sec LOCK UNLOCK UNLOCK LOCK 2 secs 2 secs UNLOCK Door control relay automatically performs the LOCK UNLOCK operation 1 to 4 times at 2 sec interval to inform the operator of the numbe...

Page 2258: ...n selecting add mode an already registered recognition code was received Proceed to continue registration If even one of the following conditions is satisfied registration of recognition codes is completed D 40 secs elapses since the door control relay response D The driver s door is opened D The key plate is inserted in the ignition key cylinder D 4 type recognition codes are registration at one ...

Page 2259: ...fts it to the manual operation in which the jam protection system is prohibited with the ignition ON 3 In the manual operation close the sliding roof completely and stop the motion 4 The fully closed position will be detected by ECU Initialization Does it become normal NG Mechanical failure OK End BE 84 BODY ELECTRICAL SLIDING ROOF SYSTEM 2005 CELICA RM1131U SLIDING ROOF SYSTEM TROUBLESHOOTING 225...

Page 2260: ...13593 Sliding Roof Assembly D Sliding Roof ECU D Sliding Roof Switch D Sliding Roof Motor Instrument Panel Junction Block D S Roof Fuse BODY ELECTRICAL SLIDING ROOF SYSTEM BE 85 2005 CELICA RM1131U LOCATION 2259 ...

Page 2261: ...tinuity 2 Ground Ignition switch LOCK or ACC No voltage 2 Ground Ignition switch ON Battery positive voltage 5 Ground Constant Battery positive voltage 7 Ground Constant Continuity 6 Ground Constant No continuity 8 Ground Ignition switch LOCK or ACC No voltage 8 Ground Ignition switch ON Battery positive voltage 9 Ground Sliding roof control switch CLOSE DOWN No continuity 9 Ground Sliding roof co...

Page 2262: ...rror Assembly D Mirror Motor Power Mirror Switch Instrument Panel Junction Block D CIG Fuse Ignition Switch BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM BE 87 2005 CELICA RM1131U POWER MIRROR CONTROL SYSTEM LOCATION 2261 ...

Page 2263: ...SIDE MIRROR SWITCH CONTINUITY Switch position Tester connection Specified condition OFF No continuity UP 3 8 6 7 Continuity DOWN 3 7 6 8 Continuity LEFT 2 8 6 7 Continuity RIGHT 2 7 6 8 Continuity If continuity is not as specified replace the switch If continuity is as specified inspect the switch circuit 3 INSPECT MIRROR MOTOR OPERATION a Connect the battery positive lead from the battery to term...

Page 2264: ...ICA RM1131U c Connect the battery positive lead to terminal 3 and the battery negative lead to terminal 5 and check that the mirror turns downward d Reverse the polarity and check that the mirror turns to the upward If operation is not as specified replace the mirror assembly 2263 ...

Page 2265: ...o broadcasts cannot be received even through AM comes in very clearly Not only does FM stereo have the smallest service area but it also picks up static and other types of interference noise easily 3 RECEPTION PROBLEMS Besides the problem of static there are also the problems called fading multipath and fade out These problems are caused not by electrical noise but by the nature of the radio waves...

Page 2266: ...path Mul tipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is re ceived directly S Fade Out Because FM radio waves are higher frequencies than AM radio waves they bounce off buildings mountains and other obstructions For this reason FM signals often seem to gradually disappear or fade away as the vehicle goes ...

Page 2267: ...enna will reach to the radio transmitted through the core wire of the coaxial cable Any noise wave other than radio wave is mixed into this core wire that causes noise in the radio and poor sound quality In order to prevent these noises from mix ing into the radio the core wire inside the coaxial cable is covered with a mesh wire called shield wire This shield wire shelters the noise and transmits...

Page 2268: ...a pencil or similar object push in the guide c Using a cleaning pen or cotton applicator soaked in clean er clean the head surface the pinch rollers and the cap stans 7 CD Player Disc Cleaning MAINTENANCE If disc gets dirty clean the disc by wiping the surface from the center to outside radially with a soft cloth NOTICE Do not use a conventional record cleaner or anti static pre servative 2267 ...

Page 2269: ...et products can be add or replace freely 3 Because of the above 2 each manufacture has been concentrated on developing products in their strongest field That enable manufactures to provide many types of products inexpensively 4 Generally a new product developed by a manufacture could not be used with other manufac tures products due to a lack of compatibility Because of this new standard users can...

Page 2270: ...ressed HINT By pressing SEEK UP switch the system enters the Service Check Mode d Service check mode 1 After the element check and switch check is completed the system enters service check mode when SEEK UP switch is pressed 2 Error codes over the tuner and connected equipments are displayed on the screen of the tuner Results for each check are displayed as follows S good No DTC is detected for bo...

Page 2271: ...Check and DTC is identified in the System Check Result Response or Diagnosis Memory Response S nrES No response is identified in the System Check Start Instruction and Request for System Check Result commands HINT S Check the present and past condition of components by performing the System Check and collecting stored DTC memories S Check results are displayed as one of the following six indicatio...

Page 2272: ...ode Refer to f CHEC CHEC Detail Display Mode Refer to g Physical Address P190 Physical Address P1A0 Old Old Detail Display Mode Refer to h Result Replacing Result Check Result Old S After the memory is cleared only the physical address is displayed cyclically SEEK UP SEEK UP SEEK UP SEEK UP SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK UP ch5 1 7 sec Indicates switch operation ch2 ch3 ch2...

Page 2273: ... chart Auxiliary Code 1 ch5 A long CLr Indicates switch operation SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK UP SEEK DOWN SEEK UP Detail code is displayed cyclically SEEK UP SEEK UP SEEK UP SEEK UP 1 Some diagnostic codes may not be displayed In this case is displayed 2 Some diag...

Page 2274: ...l Address Connection Check Code 2 SEEK UP SEEK DOWN Detail code is displayed cyclically Auxiliary Code 1 Number of Occurrence 2 SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK UP SEEK DOWN SEEK UP 1L 1d E4 2L 2d 43 2P 2n 1P 1n 2c 1c 1 ...

Page 2275: ... Address Connection Check Code 2 SEEK UP SEEK DOWN Detail code is displayed cyclically Auxiliary Code 1 Number of Occurrence 2 SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK UP SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK DOWN SEEK UP SEEK DOWN SEEK UP 1L 1d d4 2L 2d 43 2P 2n 1P 1n 2c 1c 1 S...

Page 2276: ...rom Head Unit f X D2 Periodic communication no response Error in periodic communication Wire harness and connector f X X f f AMP 440 D1 D4 Stereo component amplifier check f Transmitter error Periodic communication error D Radio receiver check D Wire harness check Communication with the equipment that is communicating has failed successively Connection confirmation has not come from the equipment ...

Page 2277: ...ing noise is produced 2 Noise present but AM FM are not operating 3 Any speaker does not work 4 Any AM or FM does not work 5 Few preset turning bands 5 Reception is poor 6 Sound quality is poor 7 Preset memory disappears 8 Tape Player Cassette tape cannot be inserted 9 Cassette tape inserted but no power 10 Power coming in but tape player does not operate 11 Any speaker does not work 12 Sound qual...

Page 2278: ...lifier Yes NG No OK No No No No OK OK OK Yes Yes Yes Yes NG NG NG Check if RADIO fuse is OK Radio assembly faulty Replace fuse ACC wire harness faulty Radio assembly faulty Replace fuse Is power supplied to BU terminal of power amplifier Is power supplied to ACC terminal of radio Is power supplied to B terminal of radio Check if GND wire harness side of power amplifier grounded normally Check if G...

Page 2279: ...y Replace fuse Does continuity exist in speaker wire harness Temporarily install another speaker Functions OK Hiss noise from speaker Yes Yes No No No Yes Power amplifier faulty Power amplifier faulty Recheck system after repair Speaker faulty Is power supplied to ACC terminal of power amplifier Check if GND wire harness side of power amplifier grounded normally Is power supplied to BU terminal of...

Page 2280: ...nctions OK Power amplifier faulty Recheck system after repair Speaker faulty 4 Radio ANY SPEAKER DOES NOT WORK Is hiss noise produced by non functioning speaker Does continuity exist in speaker wire harness Yes Yes No Yes No No 3 Radio NOISE PRESENT BUT AM FM NOT OPERATING Go to No 25 Radio faulty If radio side faulty BODY ELECTRICAL AUDIO SYSTEM BE 105 2005 CELICA RM1131U 2279 ...

Page 2281: ...mally Radio assembly faulty Is power for the antenna being output from the radio assembly Hiss noise from speaker Temporarily install another speaker Functions OK Radio assembly faulty Recheck system after repair Speaker faulty Power amplifier faulty Recheck system after repair Poor signals poor location No Yes Yes No No No Yes Yes Yes Yes No No BE 106 BODY ELECTRICAL AUDIO SYSTEM 2005 CELICA RM11...

Page 2282: ...the continuity of the antenna cord OK Check the grounding of the antenna antenna cord choke coil and noise filter See page BE 90 Does the condition get better by replacing the choke coil Does the condition get better by replacing the antenna cord Take a measure for contact An electric wave environment is bad Does the condition get better if removing them Influence of additional installation parts ...

Page 2283: ...amplifier faulty Is cassette tape inserted in tape player Check if RADIO fuse is OK Radio assembly faulty Replace fuse BU wire harness faulty GND faulty Power amplifier faulty 8 Radio PRESET MEMORY DISAPPEARS No Radio assembly faulty No No No No Yes Yes Yes Power amplifier faulty Radio assembly faulty Yes Yes Yes No No No NG NG OK OK Yes Check if GND wire harness side of power amplifier grounded n...

Page 2284: ...CC fuse is OK ACC wire harness faulty Check if RAD fuse is OK Radio assembly faulty Replace fuse Replace fuse B wire harness faulty Power amplifier faulty Radio assembly faulty No No No No OK OK Yes Yes Yes Yes NG NG Check if GND wire harness side of power amplifier grounded normally Is power supplied to BU terminal of power amplifier Check if GND wire harness side of radio assembly grounded norma...

Page 2285: ...all another speaker Functions OK Hiss noise from speaker Radio assembly faulty Recheck system after repair Yes Radio assembly faulty Recheck system after repair Radio assembly faulty No No No Yes Yes Yes Yes No Is radio operating normally Speaker wire harness faulty Speaker faulty Is hiss noise produced by non functioning speaker Does continuity exist in speaker wire harness Temporarily install an...

Page 2286: ...adio assembly faulty Does it operate normally after cleaning the heads Yes Does it operate normally after cleaning the heads Radio assembly faulty Is there any foreign objects inside tape player Cassette tape faulty Remove foreign object Head dirty 14 TAPE JAMMED MALFUNCTION WITH TAPE SPEED OR AUTO REVERSE No No No Yes Yes Yes 14 Tape Player TAPE JAMMED MALFUNCTION WITH TAPE SPEED OR AUTO REVERSE ...

Page 2287: ... assembly faulty CD player faulty Replace fuse BU wire harness faulty Check if RADIO fuse is OK Radio assembly faulty Is auto search button of radio operating normally No No Yes Yes Yes No OK NG OK OK NG NG Check if GND wire harness side of radio assembly grounded normally Is power supplied to BU terminal of power amplifier Is power supplied to BU terminal of radio receiver Is power supplied to BU...

Page 2288: ...udden temperature change occurred inside cabin CD player faulty Is temperature inside cabin hot Speaker wire harness faulty Speaker faulty Power amplifier faulty Recheck system after repair Does continuity exist in speaker wire harness Temporarily install another speaker Functions OK Hiss noise from speaker Radio assembly faulty Recheck system after repair No Yes Yes Yes Yes Yes Yes Yes Yes No No ...

Page 2289: ...Formation of condensation due to temp changes Yes Yes Yes Yes No No No No 20 CD Player SOUND QUALITY POOR VOLUME FAINT Is radio operating normally CD faulty Functions OK if different CD inserted Speaker faulty Temporarily install another speaker Functions OK Yes No Is speaker property installed CD player faulty Install properly Yes Yes Yes No No No Radio assembly or CD player or power amplifier fa...

Page 2290: ...es No No No No Radio assembly faulty Recheck system after repair CD player faulty 22 CD Player CD WILL NOT BE EJECTED Is auto search button of radio operating normally No Radio assembly faulty Replace fuse BU wire harness faulty Power amplifier faulty Radio assembly faulty Check if RADIO fuse is OK No No No Yes NG OK Yes Yes Yes Is power supplied to BU terminal of power amplifier Is power supplied...

Page 2291: ... is OK Radio assembly faulty Replace fuse ACC wire harness faulty Radio assembly faulty Replace fuse Check if GND wire harness side of power amplifier grounded normally Is power supplied to ACC terminal of power amplifier Is power supplied to BU terminal of power amplifier Is power supplied to ACC terminal of radio assembly Is power supplied to B terminal of radio assembly Check if GND wire harnes...

Page 2292: ...e fuse Is there continuity in speaker wire harness Temporarily install another speaker Functions OK Hiss noise from speaker Yes Yes No No No Yes Power amplifier faulty Power amplifier faulty Recheck system after repair Speaker faulty Is power supplied to ACC terminal of power amplifier Check if GND wire harness side of power amplifier grounded normally Is power supplied to BU terminal of power amp...

Page 2293: ...er ANY SPEAKER DOES NOT WORK Speaker wire harness faulty Speaker faulty Is hiss noise produced by non functioning speaker Does continuity exist in speaker wire harness Is radio operating normally Yes Yes Yes Yes No No No No Radio assembly faulty Recheck system after repair BE 118 BODY ELECTRICAL AUDIO SYSTEM 2005 CELICA RM1131U 2292 ...

Page 2294: ...oes the noise occur even after pulling out the defogger terminal Does the condition get better by replacing the antenna cord Noise radiates directly to the antenna from the generation source Does the condition get better by replacing the choke coil Replace the antenna cord Replace the choke coil Interfering noise from the defogger line and choke coil Grounding failure Failure of glass installation...

Page 2295: ...oise Washer noise Engine coolant temp gauge noise Wiper noise Whining noise occurs when A C is operating Scratching noise occurs during sudden acceleration driving on rough roads or when ignition switch is turned ON Clicking sound is heard when horn button is once pressed and then released Whirring grating sound is heard when holding the horn button Murmuring sound stops when engine stops Tick tac...

Page 2296: ...P 13 I25301 Tweeter Radio Assembly Instrument Panel Junction Block D CIG Fuse D RADIO Fuse Front Speakers Rear Speakers Power Amplifier BODY ELECTRICAL AUDIO SYSTEM BE 121 2005 CELICA RM1131U LOCATION 2295 ...

Page 2297: ...control switch TAIL or HEAD Battery positive voltage 3 Ground AMP Radio power switch ON Battery positive voltage 7 Ground MUTE Audio sounding 1 V or below 8 Ground FR Audio sounding 5 7 V 9 Ground FL Audio sounding 5 7 V 10 Ground GND3 Always Continuity 11 Ground ACC Ignition switch ACC Battery positive voltage 16 Ground SGND Always Continuity 17 Ground BEEP Audio sounding 18 Ground RR Audio sound...

Page 2298: ...unding 5 7 V A2 Ground FL Audio sounding 5 7 V A3 Ground ACC Ignition switch ACC Battery positive voltage A4 Ground B Always Battery positive voltage A5 Ground FR Audio sounding 5 7 V A6 Ground FL Audio sounding 5 7 V A7 Ground GND Always Continuity A10 Ground ILL Light control switch TAIL or HEAD Battery positive voltage B1 Ground RR Audio sounding 5 7 V B2 Ground RL Audio sounding 5 7 V B3 Groun...

Page 2299: ...BE1DE 09 I25302 Antenna Assembly Audio Assembly BE 124 BODY ELECTRICAL ANTENNA 2005 CELICA RM1131U ANTENNA LOCATION 2298 ...

Page 2300: ...aluminum foil with a finger By placing and moving the tester stick along the glass printed antenna check if continuity exists HINT Matching module is built in the bus bar of the glass printed an tenna main terminal side of CELICA and no continuity exists between the terminal and the antenna Therefore for the conti nuity checking of the glass printed antenna on the main anten na side of CELICA plac...

Page 2301: ...BE0151 BE 126 BODY ELECTRICAL ANTENNA 2005 CELICA RM1131U d Using a fine tip brush apply a small amount of the agent to the wire e After a few minutes remove the masking tape 2300 ...

Page 2302: ...LESHOOTING HINT Troubleshoot the clock according to the table below Troubleshooting No Passenger seat belt warning light does not come on 1 Clock does not operate 1 Clock loses or gains time 1 5 seconds day 2 1 INSPECT CLOCK CIRCUIT 2 TROUBLESHOOTING NO 1 a Turn ignition switch ON b Check that the battery positive voltage is 10 16 V If voltage is not as specified replace the battery c Check that t...

Page 2303: ...Wire Harness Side US 4 5 2 3 1 ECU ACC Fuse DOME Fuse Combination Meter PANEL 1 Fuse Ground ACC B PBEW ILL E Clock Assembly Wire Harness Side CANADA BE 128 BODY ELECTRICAL CLOCK 2005 CELICA RM1131U 3 TROUBLESHOOTING NO 2 a Turn ignition switch ON b Check that the battery positive voltage is 10 16 V If voltage is not as specified replace the battery c Inspect the error of the clock Allowable error ...

Page 2304: ...round Adjust or replace clock Below 10 V Locate cause and repair or recharge battery Yes Is there battery positive voltage between terminal ACC and body ground Below 10 V Locate cause and repair or recharge battery BODY ELECTRICAL CLOCK BE 129 2005 CELICA RM1131U 2303 ...

Page 2305: ...BE0FY 33 I13597 Engine Room Junction Block D HORN Fuse D HORN Relay Horn Horn Switch BE 130 BODY ELECTRICAL HORN SYSTEM 2005 CELICA RM1131U HORN SYSTEM LOCATION 2304 ...

Page 2306: ...and body ground when the horn contact plate is pressed against the steering spoke assembly If continuity is not as specified repair or replace the steering wheel or wire harness as necessary h Install the horn pad in place and using a torx socket wrench torque the 2 bolts Torque 7 1 N m 72 kgf cm 62 in lbf i Install the left and right covers j Connect the negative terminal to the battery 2 INSPECT...

Page 2307: ...liers Screwdriver Scraper BODY CLIP BO 1 2005 CELICA RM1131U CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below HINT If the clip is damaged during the operation always replace it with a new clip 2306 ...

Page 2308: ...V00012 Shape Example Removal Installation Removal Installation Removal Installation BO 2 BODY CLIP 2005 CELICA RM1131U 2307 ...

Page 2309: ...pas senger airbag side airbag and seat belt pretensioner Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious acci dent Before servicing including removal or installation of parts inspection or replacement be sure to read the precautionary notices in the RS section 2308 ...

Page 2310: ... Bumper Cover Lower Front Bumper Cover Front Bumper Extension Retainer Front Bumper Extension Retainer w Fog light Fog Light 20 200 14 20 200 14 Radiator Grille w Fog light Fog Light Lower Radiator Grille Side Marker Side Marker License Plate Mounting Bracket Hood To Front End Pane Symbol Emblem x8 BO 4 BODY FRONT BUMPER 2005 CELICA RM1131U FRONT BUMPER COMPONENTS 2309 ...

Page 2311: ...cement Deck Trim Side Panel No 1 Luggage Compartment Trim Hook LH Deck Trim Side Panel x 4 Rear Combination Light RH Luggage Compartment Mat No 2 Rear Bumper Energy Absorber Rear Bumper Energy Absorber Rear Bumper Cover LH Side Seal Quarter Vent Rear Combination Light LH RH Side Seal Hook 20 200 14 x 4 Hook BODY REAR BUMPER BO 5 2005 CELICA RM1131U REAR BUMPER COMPONENTS 2310 ...

Page 2312: ...BO2NB 09 H21297 Upper Front Fender Apron Seal Upper Radiator Support Seal Headlight Headlight Front Bumper Cover BO 6 BODY HEADLIGHT 2005 CELICA RM1131U HEADLIGHT COMPONENTS 2311 ...

Page 2313: ...ve the 3 bolts b Disconnect the connectors then remove the headlight as shown in the illustration c The procedure for the other side is same as above HINT At the time of installation if the bracket in the illustration is dam aged replace it to a new one to install the headlight to the body If the shown part of the headlight is damaged the headlight can be reinstalled to the body by installing a br...

Page 2314: ...BO2ND 07 BO 8 BODY HEADLIGHT 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BO 6 2313 ...

Page 2315: ...LEFT LIGHT DIRECTIONS a Adjust the hood by loosening the hood side hinge bolts b Tighten the loosened bolts again Torque 13 N m 130 kgf cm 9 ft lbf 2 ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION Adjust the hood by turning the cushions 3 ADJUST HOOD LOCK a Remove the upper front fender opron seal b Remove the upper radiator support seal c Remove the radiator reservoir d Adjust the hood lock by l...

Page 2316: ...rip Door Check Front Door Belt Moulding Upper Window Stop No 2 Door Inside Handle Bezel Door Trim Door Side Airbag Sensor Plug Hole Cover Regulator Handle Shim Speaker Door Inside Handle Remote Control Mirror Switch w o Power window w o Power door lock Service Hole Cover Front Door Inner Weatherstrip Shim Window Regulator Plate Specified torque N m kgf cm ft lbf L Precoated Part 4 9 50 43 in lbf 8...

Page 2317: ...plate and regula tor handle with the snap ring in the position within 15 as shown in the illustration 2 REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver remove the lower frame bracket garnish HINT Tape the screwdriver tip before use 3 REMOVE NO 2 DOOR INSIDE HANDLE BEZEL Using a screwdriver remove the No 2 door inside handle bezel HINT Tape the screwdriver tip before use 4 REMOVE REMOTE CONT...

Page 2318: ...oor trim 6 REMOVE DOOR SIDE AIRBAG SENSOR NOTICE S If the wiring connector of the SRS is disconnected with the ignition switch in ON or ACC position DTCs will be recorded S Never use SRS parts removed from another vehicle When replacing parts replace them with new ones S Never reuse the sensor involved in a collision where the SRS has deployed S Never repair a sensor in order to reuse it Disconnec...

Page 2319: ...ter speaker REMOVE TWEETER SPEAKER 9 REMOVE SERVICE HOLE COVER NOTICE Do not tear the cover HINT S At the time of reassembly please refer to the following item S Bring out the 2 cables and wire harness through the slits of service hole cover 10 REMOVE FRONT DOOR WEATHERSTRIP a Using a clip remover remove the 4 clips HINT Tape the screwdriver tip before use b Using a clip remover remove the front d...

Page 2320: ...s out of the panel carefully NOTICE Be careful not to drop the door glass HINT S At the time of reassembly please refer to the following item S Insert a shop rag inside the panel to prevent the glass from being scratched 14 REMOVE WINDOW REGULATOR a Remove the bolt of lower plate Torque 4 9 N m 50 kgf cm 43 in lbf b Unlock the snap by pulling the lower plate c Remove the snap and lower plate from ...

Page 2321: ...vacuum cleaner remove the drilled rivets and the associated metallic dust from the inside of the door panel CAUTION Do not touch the cut rivets and rivet cutter as they will be not NOTICE S Do not jiggle the rivet cutter while cutting S Otherwise you may enlarge the rivet hole or damage the rivet cutter HINT Do not drill the door inner hole HINT At the time of reassembly please refer to the follow...

Page 2322: ...the lower frame 19 REMOVE FRONT DOOR NO 2 WEATHERSTRIP a Using a clip remover remove the clip b Remove the front door No 2 weatherstrip 20 REMOVE DOOR LOCK a Disconnect the 2 links from the outside handle and key cylinder b w o Power door lock Remove the nut and 3 screws Torque Nut 5 4 N m 55 kgf cm 48 in lbf Screw 4 9 N m 50 kgf cm 43 in lbf c w Power door lock Disconnect the connector and remove...

Page 2323: ...he time of reassembly please refer to the following item S Apply MP grease to the sliding and rotating parts of the door lock 21 REMOVE OUTSIDE HANDLE a Remove the 2 bolts and outside handle with key cylinder Torque 5 4 N m 55 kgf cm 48 in lbf b Remove the bolt and key cylinder from the outside han dle Torque 5 4 N m 55 kgf cm 48 in lbf 2322 ...

Page 2324: ...n you close the door with the glass fully closed check that the weatherstrip is not pinched and that the door glass is not in contact with the roof drip moulding 3 When the door glass is fully closed check that the outside edge of the door glass is in contact with the weatherstrip at the front pillar and roof side and that the edge of the glass cannot be seen 4 Check that the door glass is not loo...

Page 2325: ... and vertical directions Adjust the door by loosening the door side hinge bolts Torque 25 N m 260 kgf cm 19 ft lbf c Adjust front door lock striker 1 Check that the door fit and door lock linkages are adjusted correctly 2 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer 3 Tighten the striker mounting screws again Torque 23 N m 230 ...

Page 2326: ...he glass position inside outside Shim thickness 1 0 mm 0 039 in 2 0 mm 0 079 in 3 Tighten the nuts Torque 8 3 N m 85 kgf cm 69 in lbf c Adjust the glass to the proper position forward rearward Loosen the 3 nuts of the carrier plate for adjustment d Adjust the glass to the proper position vertically With the glass fully closed Adjust the door window upper stops Torque 11 N m 115 kgf cm 8 ft lbf 232...

Page 2327: ...BO2OK 04 BODY FRONT DOOR BO 21 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 11 2326 ...

Page 2328: ... Outside Back Door Garnish Control Link Outside Back Door Handle Licence Plate Light Stopper Cushion Back Door Weatherstrip Lower Stopper Hook Specified torque N m kgf cm ft lbf Key Cylinder Rear Deck Trim Cover 8 3 85 74 in lbf 8 3 85 74 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 11 115 8 26 270 20 26 270 20 11 115 8 19 196 14 Control Cable BO 22 B...

Page 2329: ...R ARM HINT S At the time of reassembly please refer to the following items S Operate the wiper motor once and turn the wiper switch OFF S Install the rear wiper arm and tighten the nut by hand S Adjust the installation position fo the wiper arm at a point in defogger pattern S Tighten the nut Torque 5 4 N m 55 kgf cm 48 in lbf 5 REMOVE REAR WIPER MOTOR a Disconnect the connector b Unfasten the 3 b...

Page 2330: ...UTSIDE BACK DOOR HANDLE a w Power door lock Disconnect the connector b Remove the 2 nuts and outside back door handle Torque 5 4 N m 55 kgf cm 48 in lbf c Remove the control link from the outside back door han dle 10 REMOVE OUTSIDE BACK DOOR GARNISH a Remove the nut b Remove the outside back door garnish by compressing clip from the inside to disengage them 11 REMOVE LICENSE PLATE LIGHTS a Disconn...

Page 2331: ...y side hinge bolts and nuts to adjust Torque 19 N m 196 kgf cm 14 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fit and door linkages are adjusted cor rectly b Remove the luggage compartment mat c Remove the 2 hooks and rear deck trim cover d Loosen the striker mounting screws Torque 11 N m 115 kgf cm 8 ft lbf e Using a plastic hammer tap the striker to adjust f Reinstall the rear deck t...

Page 2332: ...BO2ON 02 BO 26 BODY BACK DOOR 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 23 2331 ...

Page 2333: ...to be replaced drill a 2 0 3 0 mm 0 079 0 118 in hole in the bottom of the back door stay as shown in the illustration to completely release the high pressure gas before disposing of it S When drilling chips may fly out so work carefully S The gas is colorless odorless and non toxic S When working handle the back door stay carefully Never score or scratch the exposed part of the piston rod and nev...

Page 2334: ...wl Top Seal Wiper Motor Wiper Link Assembly Specified torque N m kgf cm ft lbf Wiper Arm Head Cap 32 323 23 32 323 23 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf BO 28 BODY FRONT WIPER AND WASHER 2005 CELICA RM1131U FRONT WIPER AND WASHER COMPONENTS 2333 ...

Page 2335: ...p ventilator lou ver then disconnect the washer hoses HINT Tape the screwdriver tip before use c Remove the 2 washer nozzles from the cowl top ventilator louver 4 REMOVE WIPER MOTOR AND LINK ASSEMBLY a Disconnect the connector b Remove the 4 bolts and wiper motor and link assembly 5 REMOVE WIPER MOTOR a Using a screwdriver disconnect the wiper link from the motor HINT Tape the screwdriver tip befo...

Page 2336: ...and the surge area are within the range indicated by the hatched line A 241 9 mm 9 524 in B 219 6 mm 8 646 in C 381 2 mm 15 008 in D 102 8 mm 4 047 in E 467 9 mm 18 421 in F 265 6 mm 10 457 in G 236 3 mm 9 303 in H 475 0 mm 18 701 in I 39 mm 15 524 in J 439 6 mm 17 307 in K 237 3 mm 9 343 in L 225 2 mm 8 866 in M 69 8 mm 2 748 in N 94 4 mm 3 717 in O 258 2 mm 10 165 in P 517 5 mm 20 374 in Q 234 2...

Page 2337: ...8 0 030 in BODY FRONT WIPER AND WASHER BO 31 2005 CELICA RM1131U ADJUSTMENT ADJUST FRONT WASHER NOZZLE Using a tool like the one shown in the illustration change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield 2336 ...

Page 2338: ...ect the connector 3 INSTALL COWL TOP VENTILATOR LOUVER a Install the 2 washer nozzle to the cowl top ventilator lou ver b Connect the washer hose then install the cowl top venti lator louver with the 4 screws and 6 clips HINT Check that the 2 clips on the back side of the cowl top ventilator louver are surely fixed to the body 4 INSTALL HOOD TO COWL TOP SEAL 5 INSTALL WIPER ARMS a Operate the wipe...

Page 2339: ...r Door Pull Handle Rear Wiper Motor Back Door Trim Board Packing Center Stop Light Specified torque N m kgf cm ft lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf BODY REAR WIPER AND WASHER BO 33 2005 CELICA RM1131U REAR WIPER AND WASHER COMPONENTS 2338 ...

Page 2340: ...trim board HINT Tape the screwdriver tip before use 4 REMOVE REAR WIPER ARM 5 REMOVE REAR WIPER MOTOR a Disconnect the connector b Unfasten the 3 bolts and remove the rear wiper motor c Remove the packing 6 REMOVE REAR WASHER NOZZLE a Remove the 2 nuts b Disconnect the connector and washer hose then remove the center stop light in order A B as shown in the illustra tion c Remove the screw and rear...

Page 2341: ... 2005 CELICA RM1131U INSPECTION INSPECT WASHER NOZZLE While operating the washer check if the upper point where the washer fluid hits the back door glass and surge area are within range indicated by the hatched line A 205 mm 8 07 in B 105 mm 4 13 in 2340 ...

Page 2342: ...in order A B as shown in the illustration c Connect the connector and washer hose then install the center stop light with the 2 nuts 2 INSTALL REAR WIPER MOTOR a Install the packing b Install the rear wiper motor and fasten the 3 bolts Torque 5 4 N m 55 kgf cm 48 in lbf c Connect the connector 3 INSTALL BACK DOOR TRIM BOARD 4 INSTALL DOOR PULL HANDLE 5 INSTALL REAR WIPER ARM a Operate the wiper mo...

Page 2343: ...IPER AND WASHER BO 37 2005 CELICA RM1131U c Adjust the installation position of the wiper arm at a point in defogger pattern d Tighten the nut Torque 5 4 N m 55 kgf cm 48 in lbf 6 w Rear spoiler REMOVE REAR SPOILER 2342 ...

Page 2344: ...BO2NL 03 H12576 Roof Drip Side Moulding Roof Side Rail Weatherstrip BO 38 BODY ROOF DRIP SIDE MOULDING 2005 CELICA RM1131U ROOF DRIP SIDE MOULDING COMPONENTS 2343 ...

Page 2345: ...ROOF DRIP SIDE MOULDING BO 39 2005 CELICA RM1131U REMOVAL 1 REMOVE ROOF SIDE RAIL WEATHERSTRIP a Using a clip remover remove the 4 clips b Remove the roof side rail weatherstrip 2 REMOVE ROOF DRIP SIDE MOULDING Remove the 8 screws and roof drip side moulding 2344 ...

Page 2346: ...ding CLEAN MOULDING a Using a heat light heat the moulding to 20 30 C 68 86 F NOTICE Do not heat the moulding excessively b Remove the adhesive tape from the moulding c Wipe off stains with cleaner d Apply a new adhesive tape to the moulding 3 INSTALL ROOF DRIP SIDE MOULDING a If using a new moulding Secure the roof drip side moulding with the clip for tempo rary attachment b Install the roof drip...

Page 2347: ...77 Butyl Tape 4 Clips BODY ROOF DRIP SIDE MOULDING BO 41 2005 CELICA RM1131U 4 INSTALL ROOF SIDE RAIL WEATHERSTRIP Install the roof side rail weatherstrip with the 4 clips as shown in the illustration 2346 ...

Page 2348: ...BO2NO 02 H12580 Roof Side Moulding BO 42 BODY ROOF SIDE MOULDING 2005 CELICA RM1131U ROOF SIDE MOULDING COMPONENTS 2347 ...

Page 2349: ...face from being scratched b Using a heat light heat the moulding to 20 30 C 68 86 F NOTICE Do not heat the moulding excessively c Using a scraper pull off the roof side moulding from the front end and rear end HINT Tape the screwdriver tip before use 2 REMOVE MOULDING AND ADHESIVE a Pull off the moulding by cutting the adhesive with a knife at the front and rear ends b Remove the moulding NOTICE D...

Page 2350: ...ding CLEAN MOULDING a Using a heat light heat the moulding surface to 20 30 C 68 86 F NOTICE Do not heat the moulding excessively b Using a knife cut the remaining adhesive from the mould ing NOTICE Be careful not to damage the moulding c Wipe off stains with cleaner 3 COAT CONTRACT SURFACE OF BODY WITH PRIMER M Using a brush coat the contact surface on the body with Primer M as shown in the illus...

Page 2351: ...r both front and rear of the vehicle Front and rear end A 50 mm 1 97 in HINT When removing the moulding apply adhesive well to the part where the body sealer is removed 5 INSTALL MOULDING Push the moulding to the body NOTICE S Make sure that the body and moulding are heated to the proper temperature S Do not depress the adhesive coated parts excessive ly but just hold them down with your thumb S S...

Page 2352: ...BO1E6 06 H12582 Side Mud Guard 9 Clips BO 46 BODY SIDE MUD GUARD 2005 CELICA RM1131U SIDE MUD GUARD COMPONENTS 2351 ...

Page 2353: ...arnish Windshield Outside Moulding Hood to Cowl Top Seal Wiper Arm Wiper Arm Head Cap Front Pillar Garnish Sun Visor Holder Cowl Top Ventilator Louver Windshield Glass No 2 Stopper Map Light Lens Map Light Assembly w o Sliding roof z z z z Specified torque z Non reusable part N m kgf cm ft lbf 32 323 23 32 323 23 BODY WINDSHIELD BO 47 2005 CELICA RM1131U WINDSHIELD COMPONENTS 2352 ...

Page 2354: ...EMOVE MAP LIGHT ASSEMBLY a Remove the screw b Using a moulding remover remove the cover c Remove the screw and map light assembly then discon nect the connector 4 REMOVE SUN VISORS 5 REMOVE SUN VISOR HOLDERS 6 REMOVE INNER REAR VIEW MIRROR Remove the inner rear view mirror as shown in the illustration 7 REMOVE WIPER ARMS Remove the 2 wiper arm head caps 2 nuts and 2 wiper arms 8 REMOVE HOOD TO COW...

Page 2355: ...blocks or similar objects c w Front window defogger Disconnect the connector NOTICE Be careful not to damage the wire harness d Cut the adhesive by pulling the piano wire around it NOTICE When separating the glass take care not to damage the paint and exterior ornaments To prevent the safety pad from being scratched when removing the windshield place a plastic sheet between the piano wire and safe...

Page 2356: ...ot to damage the glass S Do not touch the glass face after cleaning it 3 w No 1 Stopper REPLACE NO 1 STOPPERS a Remove the damaged stoppers b Cut off the old adhesive around the stopper installation area NOTICE Be careful not to damage the body c Clean the installation area d Attach new stoppers to the body so that the notches on the body will align with the stoppers as shown in the il lustration ...

Page 2357: ... set per fectly even c Place reference marks on the glass and body d Remove the glass 7 CLEAN CONTACT SURFACE OF GLASS Using a cleaner clean the contact surface which is black col ored area around the entire glass rim NOTICE Do not touch the glass face after cleaning it 8 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat Primer M to the exposed part of body on the vehicle side NOTICE S...

Page 2358: ...d Primer G for later use 10 APPLY ADHESIVE a Cut off the tip of the cartridge nozzle Part No 08850 00801 or equivalent HINT After cutting off the tip use all adhesive within the time de scribed in the table below Temperature Tackfree time 35 C 95 F 15 minutes 20 C 68 F 100 minutes 5 C 41 F 8 hours b Load the cartridge into the sealer gun c Coat the glass with adhesive as shown in the illustration ...

Page 2359: ...me described in the table below Temperature Minimum time prior to driving the vehicle 35 C 95 F 1 5 hours 20 C 68 F 5 hours 5 C 41 F 24 hours 12 INSPECT FOR LEAK AND REPAIR NOTICE Conduct a leak test after the hardening time has elapsed 13 INSTALL FRONT SIDE OF ROOF HEADLINING 14 INSTALL COWL TOP VENTILATOR LOUVER HINT Check that the 2 clips on the back side of the cowl louver are surely fixed to ...

Page 2360: ...BO 54 BODY WINDSHIELD 2005 CELICA RM1131U 17 INSTALL INNER REAR VIEW MIRROR 18 INSTALL SUN VISOR HOLDERS 19 INSTALL SUN VISOR 20 INSTALL MAP LIGHT ASSEMBLY 21 INSTALL FRONT PILLAR GARNISH 2359 ...

Page 2361: ...Cushion Assembly Rear Seatback RH Roof Side Rail Weatherstrip Roof Drip Side Moulding Door Scuff Plate Quarter Trim Panel Front Seat Outer Belt Shoulder Anchor Coat Hook Roof Side Inner Garnish No 1 Luggage Compartment Trim Hook Hook Spacer z z 43 440 32 43 440 32 Specified torque z Non reusable part N m kgf cm ft lbf z 18 185 13 18 185 13 18 185 13 7 8 80 69 in lbf BODY QUARTER WINDOW GLASS BO 55...

Page 2362: ...tip before use 5 REMOVE LUGGAGE COMPARTMENT MAT 6 REMOVE REAR DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver remove the rear deck trim cover HINT Tape the screwdriver tip before use 7 REMOVE DECK TRIM SIDE PANEL a Remove the screw and No 1 luggage compartment trim hook b RH side Using a screwdriver remove the rear room light then dis connect the connect...

Page 2363: ...RONT SEAT OUTER BELT SHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 13 REMOVE ROOF SIDE INNER GARNISH a Using a screwdriver open the cap of coat hook HINT Tape the screwdriver tip before use b Remove the screw and coat hook c Using a screwdriver remove the roof side inner garnish HINT Tape the screwdriver tip before use 14 REMOVE ROOF SIDE RAIL WEATHERSTRIP a Using a clip remover remove the 4...

Page 2364: ...W GLASS 2005 CELICA RM1131U 15 REMOVE ROOF DRIP SIDE MOULDING Remove the 8 screws and roof drip side moulding 16 REMOVE QUARTER WINDOW GLASS a Using a knife cut off the moulding as shown in the below illustration NOTICE Do not damage the body with the knife b Remove the remaining moulding 2363 ...

Page 2365: ...ter surface to keep the surface from being scratched NOTICE When separating the glass take care not to damage the paint and exterior e Cut the adhesive by pulling the piano wire around it HINT Cut the adhesive areas as shown in the illustration leaving the adhesive where the clips are f Push the piano wire through as shown in the illustration cut off the adhered part to the clips g Remove the glas...

Page 2366: ...ive has been removed clean the body 2 CLEAN CONTACT SURFACE OF NEW GLASS Using a cleaner clean the contact surface which is black col ored area around the entire glass rim NOTICE Do not touch the glass face after cleaning it 3 INSTALL NEW SPACERS Install the new spacers to the quarter window glass as shown in the illustration 4 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat Primer M...

Page 2367: ...ACE OF NEW GLASS WITH PRIMER G a Using a brush or sponge coat the edge of the glass and the contact surface with Primer G as shown in the illustra tion b When the primer is coated wrongly to the area other than the specified wipe it off with a clean shop rag before the primer dries NOTICE S Allow 3 minutes or more to dry the primer coated sur face S Do not keep any of the opened Primer G for later...

Page 2368: ...zle Part No 08850 00801 or equivalent HINT After cutting off the tip use all adhesive within the time de scribed in the table below Temperature Tackfree time 35 C 95 F 15 minutes 20 C 68 F 100 minutes 5 C 41 F 8 hours b Load the cartridge into the sealer gun c Coat the new glass with adhesive as shown in the illustra tion Adhesive height 12 0 mm 0 472 in Adhesive width 8 0 mm 0 315 in 2367 ...

Page 2369: ...ivalent 9 INSTALL ROOF DRIP SIDE MOULDING See page BO 40 10 INSTALL ROOF SIDE RAIL WEATHERSTRIP See page BO 40 11 INSTALL ROOF SIDE INNER GARNISH 12 INSTALL FRONT SEAT OUTER BELT SHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 13 INSTALL QUARTER TRIM PANEL 14 INSTALL REAR SEAT OUTER BELT FLOOR ANCHOR Install the rear seat outer belt floor anchor with the bolts as shown in the illustration Torq...

Page 2370: ...r Pull Handle w Rear spoiler Rear Spoiler Back Door Trim Board Center Stop Light Rear Wiper Arm No 2 Dam No 1 Dam No 2 Dam Clip z z z z Specified torque z Non reusable part z z N m kgf cm ft lbf 5 4 55 48 in lbf BO 64 BODY BACK DOOR GLASS 2005 CELICA RM1131U BACK DOOR GLASS COMPONENTS 2369 ...

Page 2371: ...e 2 nuts b Disconnect the connector and washer hose then remove the center stop light in order A B as shown in the illustra tion 6 REMOVE BACK WINDOW OPENING TRIM 7 REMOVE BACK DOOR GLASS a Insert a piano wire between body and glass and let it pass through b Tie both wire ends to wooden blocks or similar object HINT Apply protective tape to the outer surface to keep the surface from being scratche...

Page 2372: ...n cleaner HINT Even if all the adhesive has been removed clean the body 2 CLEAN REMOVED GLASS a Place marks for installing new clips to the glass b Remove the damaged clips and dams c Using a scraper remove the adhesive sticking to the glass d Clean the glass with cleaner NOTICE S Do not touch the glass after cleaning it S Be careful not to damage the glass 3 If reusing the glass INSTALL NEW CLIPS...

Page 2373: ... a brush or sponge coat the edge of the glass and the contact surface with Primer G as shown in the illustra tion b When the primer is coated wrongly to the area other than the specified wipe it off with a clean shop rag before the primer dries NOTICE S Allow 3 minutes or more to dry the primer coated sur face S Do not keep any of the opened Primer G for later use 7 APPLY ADHESIVE a Cut off the ti...

Page 2374: ...ehicle during the time described in the table below Temperature Minimum time prior to driving the vehicle 35 C 95 F 1 5 hours 20 C 68 F 5 hours 5 C 41 F 24 hours 9 INSPECT FOR LEAKS AND REPAIR NOTICE Conduct a leak test after the hardening time has elapsed 10 INSTALL BACK WINDOW OPENING TRIM 11 INSTALL CENTER STOP LIGHT 12 INSTALL BACK DOOR TRIM BOARD 13 INSTALL DOOR PULL HANDLE 14 INSTALL REAR WI...

Page 2375: ... the operation time of the slid ing roof Operation time Approx 6 secs b Check for abnormal noise or binding during operation c With the sliding roof fully closed check for water leakage d Check for a difference in level between the sliding roof weatherstrip and roof panel Except rear end 0 1 5 mm 0 0 059 in Rear end 0 1 5 mm 0 0 059 in 0 1 0 mm 0 0 039 in 2374 ...

Page 2376: ...ar Front Housing Frame Drive Cable Roof Guide Rail Drain Hose RH Roof Drip Channel No 1 Sunshade Trim Sliding Roof Bracket 5 4 55 48 in lbf Specified torque N m kgf cm ft lbf 2 0 20 17 in lbf 2 0 20 17 in lbf 2 0 20 17 in lbf 2 0 20 17 in lbf 2 0 20 17 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf 5 4 55 48 in lbf BO 70 BODY SLIDING ROOF 2005 CELICA RM1131U COMPONENTS 2375 ...

Page 2377: ...e the drive gear with the sliding roof fully closed a Remove the 2 screws and room light bracket b Disconnect the connector c Remove the 2 bolts and drive gear Torque 5 4 N m 55 kgf cm 48 ft lbf 4 REMOVE SLIDING ROOF HOUSING a Disconnect the 4 drain hoses from the housing b Remove the 12 bolts and 6 brackets Torque 5 4 N m 55 kgf cm 48 ft lbf c Remove the 4 nuts then remove the housing Torque 5 4 ...

Page 2378: ...gf cm 17 in lbf 4 REMOVE REAR ROOF DRIP CANNEL 5 REMOVE LH AND RH ROOF DRIP CHANNEL 6 REMOVE CABLE GUIDE CASING Torque 2 0 N m 20 kgf cm 17 in lbf 7 REMOVE DRIVE CABLE a Remove the screw b Slide the drive cable rearward then remove it c Employ the same manner described above to the other side HINT At the time of reassembly please refer to the following items S Adjust the drive cable to a closed an...

Page 2379: ...ard 2 ADJUST SLIDING ROOF GLASS IN CLEARANCE Difference in left and right clearance a When the front or rear alignment is not correct remove the drive gear and sliding roof glass then adjust the drive cables NOTICE Remove the drive gear with the sliding roof fully closed b Adjust by sliding the cables forward or rearward to align the 2 marks as shown in the illustration c Install the drive gear an...

Page 2380: ...BO2O3 02 BO 74 BODY SLIDING ROOF 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 72 2379 ...

Page 2381: ...Y SLIDING ROOF BO 75 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BO 88 HINT After installing the sliding roof sliding roof need to be re initialized Refer to BE 86 2380 ...

Page 2382: ...l Name Plate Heater Control Konb Cluster Finish Panel Shift Lever Knob Upper Console Panel Upper Console Panel Radio M T Console Box LH End Finish Panel Door Scuff Plate Front Door Opening Trim Front Pillar Garnish Lower Column Cover Headlight Dimmer Switch Lower No 1 Finish Panel Upper Column Cover Wiper and Washer Switch Steering Wheel Spiral Cable Cowl Side Trim w o Power window Console Box Hol...

Page 2383: ...ozzle No 2 Heater to Register Duct No 3 Heater to Register Duct No 3 Register No 2 Register RH Lower Pad Insert No 1 Pin Automatic Light Console Sensor No 1 Register No 1 Heater to Register Duct No 1 Pin Center Bracket Light Control Rieostat Instrument Panel Wire F or G F or G F or K F or K Hazard Switch Switch Hole Cover Window Lock Switch BODY INSTRUMENT PANEL BO 77 2005 CELICA RM1131U 2382 ...

Page 2384: ...22 0 2055 L 16 0 63 ø 8 0 32 ø 6 0 24 mm in ø 5 22 0 2055 L 16 0 63 ø 5 0 20 L 18 0 71 ø 5 0 20 L 16 0 63 ø 5 0 20 L 16 0 63 ø 5 0 20 L 14 0 55 ø 4 0 16 L 16 0 63 BO 78 BODY INSTRUMENT PANEL 2005 CELICA RM1131U HINT Screw shapes and sizes are indicated in the table below The codes A N correspond to those indicated on the previous page 2383 ...

Page 2385: ...l HINT Tape the screwdriver tip before use 5 REMOVE FINISH PANEL 6 REMOVE COLUMN COVERS See page SR 13 7 REMOVE SPIRAL CABLE See page SR 13 8 REMOVE WIPER AND WASHER SWITCH AND LIGHT CONTROL SWITCH AND HEADLIGHT DIMMER SWITCH See page SR 13 9 REMOVE CLUSTER FINISH PANEL a Remove the 2 screws b Using a screwdriver remove the cluster finish panel HINT Tape the screwdriver tip before use 10 REMOVE CO...

Page 2386: ... to damage the airbag wire harness 13 REMOVE PASSENGER AIRBAG ASSEMBLY Remove the bolt 2 nuts and passenger airbag assembly Torque Bolt 20 N m 204 kgf cm 15 ft lbf 14 REMOVE UPPER CONSOLE PANEL a M T Remove the shift lever knob b Using a screwdriver remove the upper console panel the disconnect the connector HINT Tape the screwdriver tip before use 15 w Power window REMOVE POWER WINDOW CONTROL SWI...

Page 2387: ...th heater control name plate then disconnect the connector HINT Tape the screwdriver tip before use d Remove the 4 screws and clock from the center cluster finish panel e Remove the 2 screws and heater control name plate from the center cluster finish panel as shown in the illustration 20 w Radio REMOVE RADIO 21 w o Radio REMOVE STEREO OPENING COVER ASSEMBLY 22 REMOVE HEATER CONTROL AND ACCESSORY ...

Page 2388: ...wire harness clamps c Remove the J B set bolts and nuts d Using a screwdriver remove the 4 caps HINT Tape the screwdriver tip before use e Remove the 2 bolts nut 4 screws and instrument panel 27 REMOVE NO 1 AND NO 2 BRACE 28 REMOVE REINFORCEMENT a w ABS Remove the 2 nuts and ABS ECU b Remove the 3 bolts 4 nuts and reinforcement 2387 ...

Page 2389: ...GISTER DUCT 5 REMOVE NO 2 HEATER TO REGISTER DUCT 6 REMOVE NO 3 HEATER TO REGISTER DUCT 7 REMOVE AUTOMATIC LIGHT CONTROL SENSOR 8 REMOVE LIGHT CONTROL RHEOSTAT 9 REMOVE HAZARD SWITCH 10 REMOVE WINDOW LOCK SWITCH 11 REMOVE SWITCH HOLE COVER 12 REMOVE NO 1 REGISTER 13 REMOVE NO 2 REGISTERS 14 REMOVE NO 3 REGISTER 15 REMOVE RH LOWER PAD INSERT 16 REMOVE CENTER BRACKET 2388 ...

Page 2390: ...BO2O7 04 BO 84 BODY INSTRUMENT PANEL 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 83 2389 ...

Page 2391: ...BO2O8 07 BODY INSTRUMENT PANEL BO 85 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BO 79 2390 ...

Page 2392: ...k Side Hinge Rear Seatback Door Scuff Plate Cowl Side Trim Front Door Opening Trim Coat Hock Front Door Opening Trim Front Pillar Garnish Quarter Trim Panel Door Scuff Plate Cowl Side Trim Luggage Compartment Mat Hook Rear Seat Cushion Roof Side Inner Garnish Front Pillar Garnish 18 185 13 43 440 32 43 440 32 18 185 13 18 185 13 43 440 32 18 185 13 43 440 32 7 8 80 69 in lbf 7 8 80 69 in lbf Hook ...

Page 2393: ...f Headlining Front Roof Side Rail Pad Roof Headlining Sun Visor Map Light Cover Front Roof Side Rail Pad Sliding Roof Opening Trim Sun Visor Holder Sun Visor Map Light Assembly w o Sliding roof BODY ROOF HEADLINING BO 87 2005 CELICA RM1131U 2392 ...

Page 2394: ... REMOVE LUGGAGE COMPARTMENT MAT 6 REMOVE REAR DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver remove the rear deck trim cover HINT Tape the screwdriver tip before use 7 REMOVE DECK TRIM SIDE PANEL a Remove the screw and No 1 luggage compartment trim hook b RH side Using a screwdriver remove the rear room light then dis connect the connector HINT Tape the...

Page 2395: ...e manner described above to the other side 12 REMOVE FRONT SEAT OUTER BELT SHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 13 REMOVE ROOF SIDE INNER GARNISH a Using a screwdriver open the cap of coat hook HINT Tape the screwdriver tip before use b Remove the screw and coat hook c Using a screwdriver remove the roof side inner quarter HINT Tape the screwdriver tip before use d Employ the same m...

Page 2396: ...MBLY a Remove the screw b Using a moulding remover remove the cover c Remove the screw and map light assembly then discon nect the connector 19 w Sliding roof REMOVE SUN ROOF OPENING TRIM MOULDING 20 REMOVE SUN VISORS 21 REMOVE SUN VISOR HOLDERS 22 REMOVE ROOF HEADLINING a Using a clip remover remove the 5 clips b Remove the roof headlining 23 REMOVE CLIP STOPPERS 24 REMOVE FRONT ROOF SIDE RAIL PA...

Page 2397: ...BO2OB 02 BODY ROOF HEADLINING BO 91 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BO 88 2396 ...

Page 2398: ...ion Inner Shield Seat Track Cover Reclining Connecting Pipe Front Seat Cushion Shield Seat Track Cover Reclining Adjuster Release Handle Outer Track Seat Track Handle Front Seat Inner Belt E Ring w o Vertical adjuster w Vertical adjuster 37 375 27 43 440 32 21 210 15 21 210 15 37 375 27 21 210 15 37 375 27 43 440 32 43 440 32 37 375 27 21 210 15 21 210 15 21 210 15 37 375 27 43 440 32 37 375 27 43...

Page 2399: ...AL 1 REMOVE SEAT TRACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 2 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c Remove the front seat NOTICE Be careful not to damage the body 2398 ...

Page 2400: ...AT CUSHION INNER SHIELD Remove the screw and front seat cushion inner shield as shown in the illustration 5 REMOVE SEATBACK ASSEMBLY a Remove the hog rings b Zip the seatback cover open c w Side airbag assembly Turn over the wire harness protector as shown in the il lustration d w Side airbag assembly Disengage the side airbag wire harness from the seat cushion frame e w Side airbag assembly Pull ...

Page 2401: ... seatback cover from the seatback cushion 7 REMOVE FRONT SEAT INNER BELT 8 REMOVE SEAT CUSHION ASSEMBLY a Remove the 4 bolts and seat cushion assembly b Remove the hog rings c Disengage the seat cushion cover hooks and remove the seat cushion frame d Remove the seat cushion cover from the seat cushion pad 9 REMOVE SEAT TRACK HANDLE Using a screwdriver remove the seat track handle HINT Tape the scr...

Page 2402: ...the seat inspect that the outer and inner recliners are released at the same time HINT When the reclining lock position slips off disassemble the seat to adjust the position b When sliding the seat inspect that the outer and inner tracks are locked at the same time HINT When sliding lock positions slip off loosen the bolts to adjust the position 2401 ...

Page 2403: ...appens a lock error will occur 4 INSTALL SEAT CUSHION ASSEMBLY a Install the seat cushion cover to the seat cushion pad with new hog rings HINT When installing the hog rings take care to prevent wrinkles as much as possible b Install the seat cushion frame to the seat cushion cover with pad c Engage the seat cushion hooks and install new hog rings HINT When installing the hog rings take care to pr...

Page 2404: ...on e w Side airbag assembly Install the 2 nuts then engage the clamp of side airbag wire harness Torque 5 5 N m 56 kgf cm 49 in lbf 7 INSTALL SEATBACK ASSEMBLY a Install the seatback assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 ft lbf b w Side airbag assembly Insert the side airbag wire harness into the slit of seatback cover c w Side airbag assembly Engage the side airbag wire harness to...

Page 2405: ...RONT SEAT BO 99 2005 CELICA RM1131U 8 INSTALL FRONT SEAT INNER SHIELD 9 INSTALL FRONT SEAT CUSHION SHIELD 10 INSTALL RECLINING ADJUSTER RELEASE HANDLE 11 w Vertical adjuster INSTALL VERTICAL ADJUSTER KNOB 2404 ...

Page 2406: ...ct the connectors c Slide the front seat to the most front position d Tighten the bolts on the rear side temporarily starting from the bolt on the inner side tighten them com pletely Torque 37 N m 375 kgf cm 27 ft lbf e Slide the seat to the most rear position to install the bolts on the front side Torque 37 N m 375 kgf cm 27 ft lbf f Install the seat track covers 2405 ...

Page 2407: ...ge Seatback Cover LH Seatback Cushion LH Side Hinge LH Seat Cushion Cover Lock Hook x 5 Seat Cushion Pad with Frame 18 185 13 Specified torque z Non reusable part N m kgf cm ft lbf z Hog Ring 7 8 80 69 in lbf 18 185 13 18 185 13 7 8 80 69 in lbf 18 185 13 18 185 13 18 185 13 x 5 zHog Ring z Hog Ring Seatback Cushion RH Seatback Lock Seatback Lock 21 210 15 21 210 15 BODY REAR SEAT BO 101 2005 CELI...

Page 2408: ...H b Remove the 4 bolts Torque 18 N m 185 kgf cm 13 ft lbf c Remove the seatback assembly LH and RH 2 REMOVE SEAT CUSHION ASSEMBLY 3 REMOVE SIDE HINGE LH AND RH Torque 7 8 N m 80 kgf cm 69 ft lbf 4 REMOVE CENTER HINGE Torque 18 N m 185 kgf cm 13 ft lbf 5 REMOVE SEATBACK LOCK STRIKER See page BO 88 Torque 18 N m 185 kgf cm 13 ft lbf 2407 ...

Page 2409: ...e from the seatback cover with pad d Employ the same manner described above to the other side 4 REMOVE SEATBACK LOCK a Remove the 2 bolts and seatback lock b Employ the same manner described above to the other side 5 REMOVE SEATBACK COVER a Remove the hog rings and seatback cover from the seatback pad b Employ the same manner described above to the other side 6 REMOVE SEATBACK CUSHION COVER Remove...

Page 2410: ...ad HINT When installing hog rings take care to prevent wrinkles as little as possible b Employ the same manner described above to the other side 3 INSTALL SEATBACK LOCKS Torque 21 N m 210 kgf cm 15 ft lbf 4 INSTALL SEATBACK FRAME a Install the seatback frame to the seatback cover with pad b Install new hog rings HINT When installing hog rings take care to prevent wrinkles as little as possible c I...

Page 2411: ...BO1FG 04 BODY REAR SEAT BO 105 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page BO 102 2410 ...

Page 2412: ...elt Front Seat Outer Belt Front Seat Inner Belt Front Seat Cushion Inner Shield Outer 7 5 76 66 in lbf 7 8 80 69 in lbf 43 440 32 43 440 32 Specified torque N m kgf cm ft lbf Outer Front Front 43 440 32 43 440 32 18 185 13 Seat Belt Anchor Cover CRS Anchor Bracket Assembly LH 18 185 13 CRS Anchor Bracket Assembly RH w CRS Anchor w CRS Anchor Rear Seat Shoulder Belt Hanger 18 185 13 43 440 32 43 44...

Page 2413: ...whenever installing a new belt assembly verify the proper operation before installation 2 Driver s Seat Belt ELR STATIC TEST a Make sure that the belt locks when pulled out quickly b Remove the locking retractor assembly c Tilt the retractor slowly d Make sure that the belt can be pulled out at a tilt of 15 de grees or less and cannot be pulled out over 45 degrees of tilt If a problem is found rep...

Page 2414: ...tract the whole belt then pull out the belt until 200 mm 7 87 in of the belt remains in the retractor f Tilt the retractor slowly g Make sure that the belt can be pulled out at a tilt of 15 de grees or less and cannot be pulled out at over 45 degrees of tilt If a problem is found replace the assembly 2413 ...

Page 2415: ...rewdriver tip before use 2 REMOVE PACKAGE TRAY TRIM 3 REMOVE REAR SEAT See page BO 102 4 REMOVE LUGGAGE COMPARTMENT TRAY a Using a clip remover remove the 2 clips b Using a screwdriver remove the luggage compartment tray HINT Tape the screwdriver tip before use 5 REMOVE LUGGAGE COMPARTMENT MAT 6 REMOVE REAR DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver...

Page 2416: ...ER BELT SHOULDER AN CHOR 13 REMOVE FRONT SEAT OUTER BELT FLOOR AN CHOR 14 REMOVE RETRACTOR OF FRONT SEAT OUTER BELT CAUTION Never disassemble the front seat outer belt NOTICE When removing the retractor of front seat outer belt take care not to pull the seat belt pretensioner wire harness a Disconnect the pretensioner connector as shown in the illustration CAUTION When removing the seat belt prete...

Page 2417: ...r ation on the quarter trim panel S Check for cuts and cracks in wire harness and for chipping in connectors S Check for deformation of the quarter panel CAUTION For removal and installation of the front seat outer belt see page BO 109 and BO 118 2 PRETENSIONER IS ACTIVATED a Perform a diagnostic system check See page DI 884 b Perform a visual check which includes the following items with the fron...

Page 2418: ...nt seat outer belt which has an in activated pretensioner S The seat belt pretensioner produces a sizeable ex ploding sound when it activates so perform the op eration out of door and where it will not create a nui sance to nearby residents S When activating the seat belt pretensioner always use the specified SST SRS Airbag Deployment Tool Perform the operation in a place away from electrical nois...

Page 2419: ... Do not connect the yellow connector which will be connected with the seat belt pretensioner 2 Check functioning of SST Press the SST activation switch and check the LED of the SST activation switch lights up CAUTION If the LED lights up when the activation switch is not being pressed SST malfunction is probable so definitely do not use the SST b Disconnect the pretensioner connector 1 Remove the ...

Page 2420: ...ness 5 Connect the SST red clip to the battery positive terminal and the black clip to the negative termi nal d Activate the seat belt pretensioner 1 Confirm that no one is inside the vehicle or within 10 m 33 ft area around of the vehicle 2 Press the SST activation switch and activate the seat belt pretensioner HINT The seat belt pretensioner operates simultaneously as the LED of the SST activati...

Page 2421: ...tensioner HINT Have a battery ready as the power source when activating the seat belt pretensioner a Remove the front seat outer belt See page BO 109 HINT Cut the belt near the seat belt retractor b Check functioning of SST See step 1 a SST 09082 00700 09082 00740 c Install the SST 1 Connect the 2 SST then connect them to the seat belt pretensioner SST 09082 00700 09082 00740 NOTICE To avoid damag...

Page 2422: ...on switch lights up e Dispose of front seat outer belt with seat belt pretension er CAUTION S The front seat outer belt is very hot when the seat belt pretensioner is activated so leave it alone for at least 30 minutes after activation S Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner S Always wash your hands with water after completing the...

Page 2423: ...oner has been activated S If the seat belt pretensioner has been found to be faulty in troubleshooting S If the front seat outer belt has been found to be faulty during checking in items 1 b or 2 b S If the front seat outer belt has been dropped CAUTION For removal and installation of the seat belt pretensioner see page BO 109 and BO 118 Be sure to follow the correct procedure 2422 ...

Page 2424: ...LT a Install the retractor of front seat outer belt with the 2 bolts Torque Upper bolt 7 5 N m 76 kgf cm 66 in lbf Lower bolt 43 N m 440 kgf cm 32 ft lbf b Connect the pretensioner connector as shown in the il lustration c Connect the retractor switch connector 2 INSTALL FRONT SEAT OUTER BELT SHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 3 INSTALL FRONT SEAT OUTER BELT FLOOR AN CHOR Torque 4...

Page 2425: ... OR EXPOSE IT TO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYS TEM If there is not enough refrigerant in the refrigerant system oil lu brication will be insufficient and compressor burnout may occur so that care to avoid this necessary care should be taken 7 DO NOT OPEN PRESSURE MANI...

Page 2426: ...tem such as the driver and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possi bly leading to a serious accident Before servicing including re moval or installation of parts inspection or replacement be sure to read the precautionary notices in the RS section 2425 ...

Page 2427: ...ent in sight glass None sufficient or too much Refer item 3 and 4 3 No temperature difference between com pressor inlet and outlet Empty or nearly empty 1 Check for gas leakage with gas leak de tector and repair if necessary 2 Add refrigerant until bubbles disappear 4 Temperature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately af...

Page 2428: ...ue to ambient temperature conditions 1 Normally functioning refrigeration system Gauge reading Low pressure side 0 15 0 25 MPa 1 5 2 5 kgf cm2 High pressure side 1 37 1 57 MPa 14 16 kgf cm2 2 Moisture present in refrigeration system Symptom seen in refrigeration system Probable cause Diagnosis Remedy During operation pressure on low pressure side sometimes become a vacuum and sometime normal Moist...

Page 2429: ...ration system S Insufficient refrigerant in system S Refrigerant leaking 1 Check for gas leakage with gas leak detector and repair if neces sary 2 Charge proper amount of re frigerant 3 If indicated pressure value is near 0 when connected to gauge create the vacuum after inspecting and repairing the location of the leak 4 Poor circulation of refrigerant Symptom seen in refrigeration system Probabl...

Page 2430: ...dirt in expansion valve by blowing with air 3 Replace condenser 4 Evacuate air and charge new refrigerant to proper amount 5 For gas leakage from expan sion valve replace expansion valve 6 Refrigerant overcharged or insufficient cooling of condenser Symptom seen in refrigeration system Probable cause Diagnosis Remedy S Pressure too high on both low and high pressure sides S No sir bubbles seen thr...

Page 2431: ...e low pressure piping hot to the touch S Bubbles seen in sight glass Air entered in refrigeration system S Air present in refrigeration sys tem S Insufficient vacuum purging 1 Check compressor oil to see if it is dirty or insufficient 2 Evacuate air and charge new refrigerant 8 Expansion valve improperly Symptom seen in refrigeration system Probable cause Diagnosis Remedy S Pressure too high on bo...

Page 2432: ... dial at COOL position 1ZZ FE engine models M T Magnetic clutch condition Idle up speed Magnetic clutch not engaged 700 50 rpm Magnetic clutch engaged 900 50 rpm If idle speed is not as specified check Idle control system 1ZZ FE engine models A T Magnetic clutch condition Idle up speed Magnetic clutch not engaged 750 50 rpm Magnetic clutch engaged 900 50 rpm If idle speed is not as specified check...

Page 2433: ...T S After the blower motor stopped leave the cooling unit for more than 15 minutes S Expose the gas leak detector sensor the under the drain hose S When bring the gas leak detector close to the drain hose make sure that the gas leak detector does not react to the volatile gases If such reaction is unavoidable the vehicle must be lifted up c If gas leak is not detected on the drain hose remove the ...

Page 2434: ...dapters to the service valves 4 EVACUATE AIR FROM REFRIGERATION SYSTEM a Connect the vacuum pump adapter to the vacuum pump b Connect the center hose of the manifold gauge set to the vacuum pump adapter c Open both the high and low hand valves and run the vacu um pump d After 10 minutes or more check that the low pressure gauge indicates 750 mmHg 30 in Hg or more HINT If the reading 750 mmHg 30 in...

Page 2435: ... center hose to the charging cylinder CAUTION Do not open both high and low hand valves of manifold gauge set c Open the valve of charging cylinder d Press the valve core on the side of manifold gauge and expel the air inside of the center hose 2 INSPECT REFRIGERATION SYSTEM FOR LEAKS a Open the high pressure hand valve and charge refriger ant b When the low pressure gauge indicates 98 kPa 1 kgf c...

Page 2436: ...a Open the high pressure hand valve fully b Charge specified amount of refrigerant then close the high pressure hand valve HINT A fully charged system is indicated by the sight glass being free of any bubbles c Charge partially refrigeration system with refrigerant 1 Set vehicle in these condition S Running engine at 1 500 rpm S Blower speed control switch HI S Temperature control selector MAX COO...

Page 2437: ... S Cooling Fan Relay No 3 Pressure Switch Compressor Condenser A C Unit S Evaporator S Expansion Valve S Heater Radiator S Thermistor Blower Unit S Blower Motor S Blower Resistor Heater Control Assembly S Blower Speed Control Switch S A C Switch Combination Meter AIR CONDITIONING AIR CONDITIONING SYSTEM AC 13 2005 CELICA RM1131U LOCATION 2436 ...

Page 2438: ...clutch 4 Compressor lock sensor 5 Compressor 6 Pressure switch 7 Heater main relay 8 Blower speed control switch 9 Heater control assembly 10 Thermistor 11 Wire harness AC 3 AC 35 AC 35 AC 35 AC 51 AC 54 AC 68 AC 65 AC 50 No cool air comes out 1 Refrigerant volume 2 Refrigerant pressure 3 Drive belt 4 Magnetic clutch 5 Compressor lock sensor 6 Pressure switch 7 Thermistor 8 Heater control assembly...

Page 2439: ...assembly 2 Wire harness AC 65 Blinking of A C indicator 1 Compressor 2 Drive belt 3 Compressor lock sensor 4 Heater control assembly AC 35 AC 16 AC 35 AC 65 Brightness does not change when light control switch is turned 1 Headlight and taillight system 2 Heater control assembly BE 18 AC 65 2438 ...

Page 2440: ...t Wrong AC2GV 07 AC 16 AIR CONDITIONING DRIVE BELT 2005 CELICA RM1131U DRIVE BELT ON VEHICLE INSPECTION INSPECT DRIVE BELT S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves 2439 ...

Page 2441: ...1FP 03 B00145 AIR CONDITIONING DRIVE BELT AC 17 2005 CELICA RM1131U REMOVAL REMOVE DRIVE BELT Loosen the drive belt tension by turning the drive belt tensioner arm clockwise and remove the drive belt 2440 ...

Page 2442: ...00145 AC 18 AIR CONDITIONING DRIVE BELT 2005 CELICA RM1131U INSTALLATION 1 INSTALL DRIVE BELT Turning the drive belt tensioner arm clockwise and install the drive belt 2 CHECK DRIVE BELT INSTALLING CONDITION 2441 ...

Page 2443: ...ts by hand CAUTION Do not connect the wrong hoses 2 CONNECT QUICK DISCONNECT ADAPTER TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH HAND VALVE OF MANIFOLD GAUGE SET 4 REMOVE CAPS FROM SERVICE VALVE ON REFRIG ERANT LINE 5 CONNECT QUICK DISCONNECT ADAPTER TO SER VICE VALVES HINT Push the quick disconnect adapter onto the service valve then slide then slide the sleeve of the quick disconnect...

Page 2444: ...OTH HAND VALVES OF MANIFOLD GAUGE SET 2 DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT Slide the sleeve of the quick disconnect adapter upward to un lock the adapter and remove it from the service valve 3 INSTALL CAPS TO SERVICE VALVES ON REFRIGER ANT LINE 2443 ...

Page 2445: ...IGERANT LINE AC 21 2005 CELICA RM1131U REFRIGERANT LINE ON VEHICLE INSPECTION 1 INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2 INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector check for leakage of refrigerant 2444 ...

Page 2446: ...uick Joint Piping Clamp Quick Joint Compressor Condenser Liquid Tube Suction Hose Discharge Hose 10 100 7 5 4 55 48 in lbf N m kgf cm ft lbf Specified torque AC 22 AIR CONDITIONING REFRIGERANT LINE 2005 CELICA RM1131U LOCATION 2445 ...

Page 2447: ...orqued tighter than the specified torqued Part tightened N m kgf cm ft lbf Condenser x Discharge tube 5 4 55 48 in lbf Condenser x Liquid tube 5 4 55 48 in lbf Compressor x Discharge tube 10 100 7 Compressor x Suction tube 10 100 7 Expansion valve x Evaporator 5 4 55 48 in lbf 4 EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount 430 30 g 15 17 1 06 oz 5 INSPECT FOR L...

Page 2448: ...NSPECTION INSPECT FOR LEAKAGE OF REFRIGERANT a Remove the glove compartment door See page BO 79 b Remove the blower unit c Using a gas leak detector check for leakage of refrigerant If there is leakage check the tightening torque at the joints or check the evaporator expansion valve A C tube and O rings 2447 ...

Page 2449: ...or Evaporator Cover Expansion Valve z O Rings z O Rings A C Tubes Thermistor Plate Plate Clamp Heater Radiator Drain Hose N m kgf cm ft lbf Specified torque z Non reusable part z Packing 5 4 55 48 in lbf If evaporator is replaced add 40 cc 1 4 fl oz of compressor oil ND OIL 8 or equivalent AIR CONDITIONING AIR CONDITIONING UNIT AC 25 2005 CELICA RM1131U COMPONENTS 2448 ...

Page 2450: ...AIN ENGINE COOLANT FROM RADIATOR HINT It is not necessary to drain out all coolant 3 DISCONNECT LIQUID TUBE AND SUCTION HOSE a Using SST remove the 2 piping clamps SST 09870 00015 Suction tube 09870 00025 Liquid tube 1 Insert SST to piping clamp HINT Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label 2 Push down SST and release the clamp lock...

Page 2451: ...t out of the system 4 REMOVE INSTRUMENT PANEL AND REINFORCE MENT See page BO 79 5 DISCONNECT WATER HOSES FROM HEATER RA DIATOR PIPES a Using pliers grip the claw of the hose clip and slide the hose clip along the hose b Disconnect the heater hoses HINT At the time of installation please refer to the following item Push the water hose onto the heater radiator pipe as far as se cond ridge on the pip...

Page 2452: ... evaporator fins for blockage If the fins are clogged clean them with compressed air NOTICE Never use water to clean the evaporator b Check fitting for cracks or scratches If necessary repair or replace 2 INSPECT HEATER RADIATOR Inspect fins for blockage If the fins are clogged clean them with compressed air 2451 ...

Page 2453: ...joint on the engine side b Hold the removed heater hose with the end facing up pour LLC into the hose c Pour LLC until it flows into the reverse tank from the hose at the bottom d When this happens stop pouring and reinstall the heater hose to the heater pipe e Perform air bleeding in the same manner when LLC is re placed See page CO 2 HINT Note that the amount of LLC removed from the heater parts...

Page 2454: ...13892 Blower Unit Glove Compartment Parts Air Refiner Filter Blower Unit Case Blower Motor Blower Resistor Filter Case Air Inlet Control Cable AC 30 AIR CONDITIONING BLOWER UNIT 2005 CELICA RM1131U BLOWER UNIT COMPONENTS 2453 ...

Page 2455: ...NIT AC 31 2005 CELICA RM1131U REMOVAL 1 REMOVE GLOVE COMPARTMENT PARTS See page BO 79 2 REMOVE BLOWER UNIT a Disconnect the connector and air inlet control cable b Remove wire harness clamp c Remove the 2 screws 2 nuts and the blower unit 2454 ...

Page 2456: ...ASSEMBLY 1 REMOVE BLOWER RESISTOR Remove the 2 screws and blower resistor 2 REMOVE AIR REFINER FILTER a Pull out the filter cover b Remove the filter from the frame 3 REMOVE BLOWER MOTOR a Remove the screw and wire harness clamp b Remove the 3 screws and the blower motor 2455 ...

Page 2457: ...AC1G8 02 AIR CONDITIONING BLOWER UNIT AC 33 2005 CELICA RM1131U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 32 2456 ...

Page 2458: ...AC1G9 02 AC 34 AIR CONDITIONING BLOWER UNIT 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page AC 31 2457 ...

Page 2459: ...ny leakage replace the compressor assembly 4 INSPECT COMPRESSOR LOCK SENSOR RESIS TANCE a Disconnect the compressor connector b Measure resistance between terminals 1 and 2 Standard resistance 165 205 Ω at 20 C 68 F If resistance is not as specified replace the sensor 5 CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 6 CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR ROTOR 7 INSPECT MAGNETIC CLUTCH BEA...

Page 2460: ...Z FE Cruise Control Actuator Compressor Drive Belt Suction Hose Discharge Hose 10 100 5 z O Rings 25 250 18 Compressor 13 2 135 9 Pressure Plate Shim z Snap Ring Rotor Stator 2ZZ GE Air Pump Assembly AC 36 AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH 2005 CELICA RM1131U COMPONENTS 2459 ...

Page 2461: ...M REFRIGERATION SYSTEM 5 REMOVE DRIVE BELT See page AC 17 6 1ZZ FE REMOVE CRUISE CONTROL ACTUATOR See page CO 27 7 2ZZ GE REMOVE AIR PUMP ASSEMBLY See page CO 27 8 DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system 9 REMOVE COMPRESSOR a Disconnect the connector b Disconnect the ...

Page 2462: ...OVE PRESSURE PLATE a Using SST and a socket wrench remove the shaft bolt SST 07112 76060 Torque 13 2 N m 135 kgf cm 9 ft lbf b Install SST on the pressure plate SST 07112 66040 c Using SST and socket wrench remove the pressure plate SST 07112 66040 07112 76060 d Remove the shims from the pressure plate 2 REMOVE ROTOR a Using SST remove the snap ring SST 95994 10020 2461 ...

Page 2463: ...TCH AC 39 2005 CELICA RM1131U b Using a plastic hammer tap the rotor off the shaft NOTICE Be careful not to damage the pulley when tapping on the ro tor 3 REMOVE STATOR a Disconnect the connector from the stator b Using SST remove the snap ring SST 95994 10020 c Remove the stator 2462 ...

Page 2464: ...GNETIC CLUTCH 2005 CELICA RM1131U REASSEMBLY 1 INSTALL STATOR a Install the stator b Using SST install the snap ring SST 95994 10020 NOTICE The snap ring should be installed so that its beveled side faces up c Connect the connector to the stator 2 INSTALL ROTOR a Install the rotor b Using SST install the snap ring SST 95994 10020 2463 ...

Page 2465: ...aft bolt SST 07112 66040 07112 76060 Torque 13 2 N m 135 kgf cm 9 ft lbf 4 INSPECT MAGNETIC CLUTCH CLEARANCE a Set the dial indicator to the pressure plate of the magnetic clutch b Connect the magnetic clutch lead wire to the positive terminal of the battery c Check the clearance between the pressure plate and ro tor when connecting the negative terminal to the bat tery Standard clearance 0 45 0 1...

Page 2466: ... Lubricate 2 new O rings with compressor oil and install them to the hoses b Connect the both hoses with 2 bolts Torque 10 N m 100 kgf cm 7 ft lbf NOTICE Hose should be connected immediately after the caps have been removed 3 1ZZ FE INSTALL CRUISE CONTROL ACTUATOR See page CO 30 4 2ZZ GE INSTALL AIR PUMP ASSEMBLY See page CO 30 5 INSTALL AND CHECK DRIVE BELT See page AC 18 AC 16 6 CONNECT NEGATIVE...

Page 2467: ...the fins are clogged wash them with water and dry with compressed air NOTICE Be careful not to damage the fins If the fins are bent straighten them with a screwdriver or pliers 2 INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage of refrigerant If there is leakage check the tightening torque at the joints 2466 ...

Page 2468: ...usable part Compressor oil ND OIL 8 or equivalent Radiator Upper Mounting Discharge Hose z O Ring z O Ring Liquid Tube 5 4 55 48 in lbf Front Bumper Drier Filter Cap 12 3 125 9 z O Ring Condenser Condenser AC 44 AIR CONDITIONING CONDENSER 2005 CELICA RM1131U COMPONENTS 2467 ...

Page 2469: ...e BO 4 3 REMOVE LIQUID TUBE AND DISCHARGE HOSE Remove 2 bolts and both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture out of the system HINT Lubricate 2 new O rings with compressor oil and install them to the tubes 4 REMOVE RADIATOR UPPER MOUNTINGS Remove the 2 bolts 2 nuts and the 2 upper mountings 5 REMOVE CONDENSER Pull out the condenser HINT ...

Page 2470: ...Insert a new dryer into the modulator NOTICE S Do not remove the dryer from a vinyl bag until insert ing it into the modulator S Install the dryer with its 2 layered part faced upward to the modulator e Insert the filter into the modulator NOTICE Install the filter with its protrusion faced downward to the modulator f Install the cap to the modulator 1 Apply compressor oil to the o rings and screw...

Page 2471: ...AC1GL 02 AIR CONDITIONING CONDENSER AC 47 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page AC 45 2470 ...

Page 2472: ...con nector b Remove the 3 screws and motor 3 INSPECT BLOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 then check that the motor op erations smoothly If operation is not as specified replace the blower motor 4 INSTALL BLOWER MOTOR a Install the motor and 3 screws b Connect the connector and wire harness clamp 5 INSTALL GLOVE COMPART...

Page 2473: ... Disconnect the connector b Remove the 2 screws and the blower resistor 2 INSPECT BLOWER RESISTOR CONTINUITY Condition Tester connection Specified condition Constant 1 2 3 4 Continuity If continuity is not as specified replace the blower resistor 3 INSTALL BLOWER RESISTOR a Install the blower resistor and 2 screws b Connect the connector 2472 ...

Page 2474: ...nect the connector b Using a screwdriver pull out the thermistor HINT Tape the screwdriver tip before use 3 INSPECT THERMISTOR a Place the thermistor in cold water and while changing the temperature of water measure resistance at the connec tor and at the same time measure temperature of water with a thermometer b Compare the 2 readings on the chart If resistance is not as specified replace the th...

Page 2475: ...00 RPM 4 Magnetic clutch control INSPECT PRESSURE SWITCH OPERATION a Connect the positive lead from the ohmmeter to termi nal 4 and the negative lead to terminal 1 b Check continuity between terminals when refrigerant pressure is charged as shown in the illustration If operation is not as specified replace the pressure switch 5 Condenser fan control INSPECT PRESSURE SWITCH OPERATION a Connect the ...

Page 2476: ...spect for leakage of refrig erant Specified amount 430 30 g 15 17 1 06 oz 2 REMOVE PRESSURE SWITCH a Disconnect the connector b Remove the pressure switch from the liquid tube Torque 10 N m 100 kgf cm 7 ft lbf HINT S Lock the switch mount on the tube with an open end wrench being careful not to deform the tube and remove the switch S At the time of installation please refer to the following item L...

Page 2477: ...AC1GW 03 AIR CONDITIONING PRESSURE SWITCH AC 53 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page AC 52 2476 ...

Page 2478: ...M1131U HEATER MAIN RELAY INSPECTION 1 REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK NO 1 2 INSPECT HEATER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 3 2 4 Continuity Apply B between terminals 1 and 3 4 5 Continuity If continuity is not as specified replace the relay 2477 ...

Page 2479: ...CA RM1131U MAGNETIC CLUTCH RELAY INSPECTION 1 REMOVE MAGNETIC CLUTCH RELAY FROM ENGINE ROOM J B 2 INSPECT MAGNETIC CLUTCH RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 2478 ...

Page 2480: ... FAN RELAY NO 3 FROM ENGINE ROOM J B 3 INSPECT COOLING FAN RELAY NO 2 CONTINUITY Condition Tester connection Specified condition Constant 1 2 4 5 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 4 INSPECT COOLING FAN RELAY NO 3 CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals ...

Page 2481: ...coolant temperature 98 C 208 F or above Rotate High speed Refrigerant pressure is less than 1 520 kPa 15 5 kgf cm2 220 psi Rotate Low speed Refrigerant pressure is 1 520 kPa 15 5 kgf cm2 220 psi or above Rotate High speed If operation is not as specified proceed to the next inspection 2 INSPECT CONDENSER FAN MOTOR OPERATION a Disconnect the condenser fan motor connector b Connect battery and ammet...

Page 2482: ...ric Cooling Fan MAF Sensor Connector Air Cleaner Cap Air Filter Air Cleaner Case Bumper Cover VSV for EVAP 2ZZ GE Air Pump Assembly 1ZZ FE Cruise Control Actuator Upper Radiator Support Bushing 8 0 82 71 in lbf 5 5 56 49 in lbf 5 0 51 44 in lbf 68 693 50 6 9 70 60 in lbf 9 8 100 87 in lbf 10 102 88 in lbf 5 0 51 41 in lbf 5 0 51 44 in lbf N m kgf cm ft lbf Specified torque AC 58 AIR CONDITIONING C...

Page 2483: ...I14013 Fan Motor Fan Shroud Fan Nut AIR CONDITIONING CONDENSER FAN AC 59 2005 CELICA RM1131U 2482 ...

Page 2484: ...IT a Disconnect the connector from the combination mater and inspect the connector on the wire harness side as shown in the chart below Test condition Turn ignition switch to ON Tester connection Condition Specified condition A7 Ground Constant Continuity A6 A18 Evaporator temperature at 25 C 77 F 1 5 kΩ If circuit is as specified try replacing the amplifier with a new one If the circuit is not as...

Page 2485: ... Specified condition B10 Ground A C switch ON Blower motor operate Below 1 0 V A C switch OFF Battery positive voltage B14 Ground Mode selector DEF Below 1 0 V Mode Selector Except DEF Battery positive voltage B15 Ground A C switch ON Below 1 0 V A C switch OFF Battery positive voltage A13 Ground Blower motor Operate Below 2 0 V Blower motor No operate Battery positive voltage If circuit is as spe...

Page 2486: ...r of ECM from the back side as shown in the chart below Tester connection Condition Specified condition E3 12 Ground Start engine Magnetic clutch ON Below 1 0 V Start engine Magnetic clutch OFF Battery positive voltage E4 28 Ground Start engine A C switch ON Battery positive voltage Start engine A C switch OFF No voltage E4 18 Ground Refrigerant pressure 196 1 340 kPa Battery positive voltage Refr...

Page 2487: ...AC2HB 02 AIR CONDITIONING AIR CONDITIONING AMPLIFIER AC 63 2005 CELICA RM1131U REMOVAL 1 REMOVE COMBINATION METER See page BE 48 2 REMOVE ECM 2486 ...

Page 2488: ...AC2HC 02 AC 64 AIR CONDITIONING AIR CONDITIONING AMPLIFIER 2005 CELICA RM1131U INSTALLATION Installation is in the reverse order of removal See page AC 63 2487 ...

Page 2489: ...ON VEHICLE INSPECTION INSPECT HEATER CONTROL DIALS OPERATION Turn the control lever and 2 control dials left and right then check that click sound can be heard and recoil is felt If click sound can not be heard or recoil is felt adjust the control cable or check control cable and heater control assembly 2488 ...

Page 2490: ...lor Blue Air Inlet Control Cable Color Gray Defroster Mode Switch Air Mix Control Cable Color Black Heater Control Cover Switch Circuit Center Cluster Finish Panel Upper Console Panel Knobs Heater Control Assembly Retainer Bulb AC 66 AIR CONDITIONING HEATER CONTROL ASSEMBLY 2005 CELICA RM1131U COMPONENTS 2489 ...

Page 2491: ... 1 REMOVE CENTER CLUSTER FINISH PANEL See page BO 79 2 DISCONNECT HEATER CONTROL CABLES NOTICE When the air mix damper control cables is disconnected should not bend the cable 3 REMOVE HEATER CONTROL ASSEMBLY Release the 2 claws and pull out the A C control assembly then disconnect the connector 4 REMOVE HEATER CONTROL PANEL a Remove the 2 screws b Slide and remove the A C control assembly 2490 ...

Page 2492: ...f continuity exists replace the heater control If no continuity exists replace the bulb 3 INSPECT A C INDICATOR OPERATION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 3 and 10 b Push the A C button in and then check that the indicator lights up If operation is not as specified replace the switch 4 INSPECT DIMMING OPERATION a Connect the positive lead...

Page 2493: ...inuity is not as specified replace the bulb 6 INSPECT BLOWER SPEED CONTROL SWITCH CON TINUITY Position Circuit Tester connection Specified condition OFF No continuity LO 1 8 Continuity M1 1 6 8 Continuity M2 1 5 8 Continuity HI 1 4 8 Continuity If continuity is not as specified replace the switch 7 INSPECT DEFROSTER MODE SWITCH OPERATION Position Circuit Tester connection Specified condition OFF N...

Page 2494: ...TER CONTROL ASSEMBLY 2005 CELICA RM1131U INSTALLATION 1 INSTALL A C CONTROL PANEL Install the A C control panel and 2 screws 2 INSTALL A C CONTROL ASSEMBLY a Install the A C control assembly temporarily b Pass through the A C control cables as shown in the il lustration c Fit the 2 claws of heater control assembly in the instru ment panel hole 2493 ...

Page 2495: ... outer cable HINT Lock the clamp while lightly pushing the outer cable to the direc tion shown by arrow in the illustration e Adjust air mix damper control cable Set air mix damper control lever to MAX COOL position and connect the inner cable to lever pin and clamp the outer cable HINT Lock the clamp while lightly pushing the outer cable to the direc tion shown by arrow in the illustration f Adju...

Page 2496: ...ssary to drain out all the coolant 2 REMOVE ECT SWITCH 3 INSPECT SWITCH CONTINUITY a Using an ohmmeter check that no continuity exists be tween the terminals when the coolant temperature is above 90 C 194 F b Using an ohmmeter check that continuity exists between the terminals when the coolant temperature is below 83 C 181 F If no continuity exists replace the switch 4 INSTALL ECT SWITCH 5 REFILL ...

Page 2497: ...NER FILTER a Remove the 2 pins in the glove box and open the glove box widely by pulling it down b Pull out the filter case c Remove the air refiner filter from the filter case 2 INSTALL AIR REFINER FILTER a Install the air refiner filter to filter case b Install the filter case c Close the glove box and install the 2 pins to it 2496 ...

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