Toyota RM787U Service And Repair Manual Download Page 127

Page: 127 / 1976

SS03Z-01

SS-24

SERVICE SPECIFICATIONS

CHARGING

139

Author:

Date:

2001 SIENNA (RM787U)

TORQUE SPECIFICATION

Part tightened

N·m

kgf·cm

ft·lbf

Bearing retainer x Drive end frame

3.0

27 in.·lbf

Rectifier end frame x Drive end frame

4.5

40 in.·lbf

Cord clip x Rectifier end frame

5.4

48 in.·lbf

Generator pulley x Rotor

110.5

1,125

Rectifier holder x Coil lead on rectifier end frame

2.9

26 in.·lbf

Voltage regulator and brush holder x Rectifier end frame

2.0

18 in.·lbf

Plate terminal x Rectifier holder

Nut

Screw

4.4

3.9

39 in.·lbf

35 in.·lbf

Rear end cover x Rectifier holder

4.4

39 in.·lbf

Terminal insulator x Rectifier holder

4.1

36 in.·lbf

Generator x Generator bracket

570

Generator x Adjusting bar

180

Summary of Contents for RM787U

Page 1: ...TICE 1 Malfunction symptoms of the supplemental re straint system are difficult to confirm so the diag nostic trouble codes become the most important source of information when troubleshooting When tr...

Page 2: ...eat belt pre tensioner have been dropped or if there are cracks dents or other defects in the case bracket or con nector replace them with new ones 8 Do not directly expose the airbag sensor assembly...

Page 3: ...Never measure the resistance of the airbag squib This may cause the airbag to deploy which is very dangerous 3 Grease should not be attached to the steering wheel pad and the pad should not be cleaned...

Page 4: ...the airbag to deploy which is very dangerous 3 Grease should not be applied to the front passen ger airbag assembly and the airbag door should not be cleaned with detergents of any kind 4 Store the ai...

Page 5: ...he airbag to deploy which is very dangerous 3 Grease should not be applied to the side airbag as sembly and the surface should not be cleaned with detergents of any kind 4 Store the airbag assembly wh...

Page 6: ...ner where the ambient temperature remains below 80 C 176 F and away from electrical noise without high humidity 5 When using electric welding first disconnect the connector yellow color and 2 pins bef...

Page 7: ...could cause undesired ignition of the supplemental restraint sys tem 3 Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK posi tion and the negative terminal...

Page 8: ...ause the engine to misfire and create an extra load on the converter f Avoid coasting with ignition turned off g Do not dispose of used catalyst along with parts contaminated with gasoline or oil 3 IF...

Page 9: ...OYOTA hand held tester one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand held tester 5 FOR VEHICLES EQUIPPED WITH POWER SLIDE DOOR CONTROL SYSTEM When...

Page 10: ...ng on the VSC related operation make sure to check that the preparations before and after work are completed according to the following instruction When using a 2 wheel drum tester such as a speedomet...

Page 11: ...ge 1 Engine DI 1 2 Automatic Transaxle DI 155 3 Tire Pressure Warning System DI 207 4 Anti Lock Brake System DI 218 5 ABS with EBD BA TRAC VSC System DI 257 6 Supplemental Restraint System DI 356 7 Po...

Page 12: ...d 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 r...

Page 13: ...ccelerator 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 IN 22 INTRODUCTION HOW TO...

Page 14: ...ubleshooting Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly By using these check functions the problem areas can be narrowed...

Page 15: ...ic 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 th...

Page 16: ...ming the 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 onl...

Page 17: ...r 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 vehic...

Page 18: ...e 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 i...

Page 19: ...combustion 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 pum...

Page 20: ...eformed 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 se...

Page 21: ...tor back side with harness Ignition Switch LOCK OFF Ignition Switch START LOCK Ignition Switch ON Ignition Switch ACC START ON ACC Indicates the place to check the voltage or resistance Indicates the...

Page 22: ...codes 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 and a connector terminal pu...

Page 23: ...terminals of the connectors Resistance 1 or less HINT Measure the resistance while lightly shaking the wire harness vertically and horizontally 4 RESISTANCE CHECK SHORT CIRCUIT CHECK a Disconnect the...

Page 24: ...eck or 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 t...

Page 25: ...Between Terminal 1 of connector A and Body Ground 5V Between Terminal 1 of connector B and Body Ground 0V Between Terminal 1 of connector C and Body Ground Then it is found out that there is an open...

Page 26: ...Between 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 AN...

Page 27: ...ng of each section a General Description is given that pertains to all repair operations con tained in that section Read these precautions before starting any repair task 3 TROUBLESHOOTING TROUBLESHOO...

Page 28: ...n be read at a glance when necessary and the text below it provides detailed informa tion Important specifications and warnings always stand out in bold type 6 REFERENCES References have been kept to...

Page 29: ...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 illustratio...

Page 30: ...le ends with a clean shop rag Do not scrape them with a file or oth er abrasive objects 5 Install the cable ends to the battery terminals after loosening the nut and tighten the nut after installa tio...

Page 31: ...l g When necessary use a sealer on gaskets to prevent leaks h Carefully observe all specifications for bolt tightening torques Always use a torque wrench i Use of special service tools SST and special...

Page 32: ...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 To disconnect vacuum h...

Page 33: ...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 te...

Page 34: ...and rear make sure the car is not carrying any extra weight Safety stand and swing arm type lift NOTICE Do not jack up at the center of the rear axle beam If the vehicle is lifted at the center of the...

Page 35: ...plate with the attachment lower ends A C Align the attachment upper end B with the front jack supporting point L Attachment dimensions 85 mm 3 35 in 70 mm 2 76 in 200 mm 7 87 in 100 mm 3 94 in C NOTI...

Page 36: ...proximately 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 Compensa...

Page 37: ...Unit ED Electro Deposited Coating EDIC Electric Diesel Injection Control EDU Electronic Driving Unit EFI Electronic Fuel Injection E G Engine EGR VM Egr Vacuum Modulator ELR Emergency Locking Retracto...

Page 38: ...Independent 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 Dr...

Page 39: ...ing 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 Driv...

Page 40: ...ion TMC TOYOTA Motor Corporation TMMK TOYOTA Motor Manufacturing Kentucky Inc TRAC Traction Control System TURBO Turbocharge U D Underdrive U S Undersize VCV Vacuum Control Valve VENT Ventilator VIN V...

Page 41: ...ta Link 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...

Page 42: ...ory O2S 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...

Page 43: ...static Vacuum 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...

Page 44: ...50 kgf cm 134 ft lbf Rear axle beam assembly to body mounting nuts Torque 88 N m 900 kgf cm 65 ft lbf 2 FINAL INSPECTION a Check the operation of the body parts Hood Auxiliary catch operates properly...

Page 45: ...abnormal noises Check that the vehicle does not wander or pull to one side Check that the brakes work properly and do not drag Do setting of the parking brake shoes and drum c Be sure to deliver a cl...

Page 46: ...or left before checking the front brake a Check all brake lines and hoses for Damage Wear Deformation Cracks Corrosion Leaks Bends Twists b Check all clamps for tightness and connections for leak age...

Page 47: ...e 5 INSPECT BALL JOINTS AND DUST COVERS a Inspect the ball joints for excessive looseness 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 fr...

Page 48: ...essively dirty or oily b Clean the air filter with compressed air First blow from the inside thoroughly then blow off the outside of the air filter 5 REPLACE AIR FILTER Replace the air filter with a n...

Page 49: ...t 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 warnin...

Page 50: ...Check that the pedal has the proper reserve distance and freeplay c Check the brake booster function 15 BRAKES At a safe place check that the brakes do not pull to one side when applied 16 PARKING BR...

Page 51: ...rs first the odometer reading miles or the time interval months Maintenance service after the last period should be performed at the same interval as before unless otherwise noted Failure to do even o...

Page 52: ...OLYTE LEVEL Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case 6 BRAKE FLUID LEVEL Check that the brake fluid level is near the upper level li...

Page 53: ...DITIONING 114 Author Date 2001 SIENNA RM787U EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Thermometer Thermistor ECT switch 3 4 W test bulb Power transistor Torque wrench Dial indicator Magnetic clu...

Page 54: ...001 SIENNA RM787U LUBRICANT Item Capacity Classification Compressor oil ND OIL 8 or equivalent When replacing receiver 20 cc 0 71 fl oz When replacing condenser 40 cc 1 4 fl oz When replacing evaporat...

Page 55: ...PP0RD 01 PREPARATION AIR CONDITIONING PP 61 113 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09216 00021 Belt Tension Gauge...

Page 56: ...uick Disconnect Adapter High pressure side 07117 58090 Quick Disconnect Adapter Low pressure side 07117 88060 Refrigerant Charging Hose High pressure side Color Red 07117 88070 Refrigerant Charging Ho...

Page 57: ...XLE 80 Author Date 2001 SIENNA RM787U EQUIPMENT Straight edge Torque converter clutch Vernier calipers Torque converter clutch Dial indicator or dial indicator with magnetic base Drive plate Hexagon W...

Page 58: ...XLE PP 29 81 Author Date 2001 SIENNA RM787U LUBRICANT Item Capacity Classification Automatic transaxle fluid Dry fill Drain and refill 8 0 liters 8 4 US qts 7 0 Imp qts 4 75 liters 5 0 US qts 4 2 Imp...

Page 59: ...PP0BB 03 PREPARATION AUTOMATIC TRANSAXLE PP 27 79 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09090 04020 Engine Sling Device...

Page 60: ...e gear shaft oil seal 09316 6001 1 Transmission Transfer Bearing Replacer RH side bearing 09316 0001 1 Replacer Pipe RH side gear shaft oil seal 09350 32014 TOYOTA Automatic Transmission Tool Set 0935...

Page 61: ...Voltmeter Ammeter Ohmmeter Test lead Syphon Brake fluid level warning switch Bulb 3 4 W Fuel sender gauge Seat belt warning relay Bulb 21 W Turn signal flasher relay Dry cell battery Fuel sender gauge...

Page 62: ...3 105 Author Date 2001 SIENNA RM787U 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 r...

Page 63: ...PP0R7 01 PREPARATION BODY ELECTRICAL PP 55 107 Author Date 2001 SIENNA RM787U SSM Special Service Materials 08888 88888 DuPont Paste No 4817 or equivalent Rear window defogger...

Page 64: ...PP0KY 01 PP 52 PREPARATION BODY ELECTRICAL 104 Author Date 2001 SIENNA RM787U BODY ELECTRICAL SST Special Service Tools 09843 18020 Diagnosis Check Wire...

Page 65: ...d surface damage Double stick tape Adhesive Cleaner Shop rag Knife Sealer gun Brush Putty spatula Glass plate or similar object Wooden block or similar object Heat light Piano wire Rope no projections...

Page 66: ...PP0B0 01 PREPARATION BODY PP 59 111 Author Date 2001 SIENNA RM787U LUBRICANT Item Capacity Classification MP grease...

Page 67: ...DY PP 57 109 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09050 20010 Air Riveter 09050 02010 Dust Cap 09050 02030 Nose Piece No 2 09050 00032 Air Drill 09050 00210 Chuck Set 09050 00220 Handle 09...

Page 68: ...PREPARATION BODY 108 Author Date 2001 SIENNA RM787U BODY SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00740 Airbag Deployment Wire Sub harness No 2 09812 00010 Door Hinge Se...

Page 69: ...PP0RA 02 PREPARATION BRAKE PP 39 91 Author Date 2001 SIENNA RM787U EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Vernier calipers Brake drum Brake drum gauge Brake drum...

Page 70: ...PP0RB 03 PP 40 PREPARATION BRAKE 92 Author Date 2001 SIENNA RM787U LUBRICANT Item Capacity Classification Brake fluid SAE J1703 or FMVSS No 116 DOT3...

Page 71: ...PP0R9 03 PP 38 PREPARATION BRAKE 90 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09905 00013 Snap Ring Pliers...

Page 72: ...10 mm 09268 46021 Nozzle Holder Retaining Nut Wrench 09703 30010 Brake Shoe Return Spring Tool 09709 29018 LSPV Gauge Set 09718 00010 Shoe Hold Down Spring Driver 09737 00010 Brake Booster Push Rod G...

Page 73: ...PARATION CHARGING PP 25 77 Author Date 2001 SIENNA RM787U EQUIPMENT Ammeter A Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor Sli...

Page 74: ...PP07B 02 PP 24 PREPARATION CHARGING 76 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester...

Page 75: ...Bearing Cone Replacer Rotor rear bearing cover 09286 4601 1 Injection Pump Spline Shaft Puller Rectifier end frame 09820 00021 Alternator Rear Bearing Puller 09820 00030 Alternator Rear Bearing Repla...

Page 76: ...COOLING PP 13 65 Author Date 2001 SIENNA RM787U COOLANT Item Capacity Classification Engine coolant w o Rear Heater w Rear Heater 9 5 liters 10 0 US qts 8 4 lmp qts 10 4 liters 11 0 US qts 9 2 lmp qts...

Page 77: ...PP06Y 01 PP 12 PREPARATION COOLING 64 Author Date 2001 SIENNA RM787U EQUIPMENT Heater ECT switch Radiator cap tester Thermometer ECT switch Torque wrench...

Page 78: ...PP06X 04 PREPARATION COOLING PP 1 1 63 Author Date 2001 SIENNA RM787U COOLING RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester...

Page 79: ...PP06S 04 PREPARATION EMISSION CONTROL PP 7 59 Author Date 2001 SIENNA RM787U EMISSION CONTROL EQUIPMENT Hose clipper MITYVAC Hand held vacuum pump Torque wrench...

Page 80: ...cator Dye penetrant Engine tune up tester Groove cleaning tool Heater Magnetic finger Micrometer OBDII scan tool Pin hole grinder Piston pin hole Piston ring compressor Piston ring expander Plastigage...

Page 81: ...or Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09040 0001 1 Hexagon Wrench Set 09090 04020 Engine Sling Device For suspending engine 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the...

Page 82: ...Replacer 09202 70020 Valve Spring Compressor 09202 00010 Attachment 09213 54015 Crankshaft Pulley Holding Tool 91651 60855 Bolt 09222 30010 Connecting Rod Bushing Remover Replacer 09223 00010 Cover Se...

Page 83: ...ch Socket Knock sensor 09843 18020 Diagnosis Check Wire 09950 50012 Puller C Set 09951 05010 Hanger 150 Crankshaft pulley Crankshaft timing pulley 09952 05010 Slide Arm Crankshaft pulley Crankshaft ti...

Page 84: ...7U 09951 07100 Handle 100 Valve guide bushing Crankshaft rear oil seal 09960 10010 Variable Pin Wrench Set 09962 01000 Variable Pin Wrench Arm Assy Camshaft timing pulley Camshaft sub gear 09963 01000...

Page 85: ...PP076 01 PREPARATION IGNITION PP 19 71 Author Date 2001 SIENNA RM787U EQUIPMENT Megger insulation resistance meter Spark plug Spark plug cleaner...

Page 86: ...PP075 04 PP 18 PREPARATION IGNITION 70 Author Date 2001 SIENNA RM787U IGNITION RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit...

Page 87: ...PP072 01 PP 16 PREPARATION LUBRICATION 68 Author Date 2001 SIENNA RM787U EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench...

Page 88: ...ill Drain and refill w Oil filter change w o Oil filter change 5 2 liters 5 5 US qts 4 6 lmp qts 4 7 liters 5 0 US qts 4 1 lmp qts 4 5 liters 4 8 US qts 4 0 lmp qts API grade SJ Energy Conserving or I...

Page 89: ...PP071 04 PREPARATION LUBRICATION PP 15 67 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09200 00010 Engine Adjust Kit...

Page 90: ...Author Date 2001 SIENNA RM787U LUBRICATION SST Special Service Tools 09032 00100 Oil Pan Seal Cutter No 2 oil pan 09223 00010 Cover Seal Replacer Crankshaft front oil seal 09228 07501 Oil Filter Wren...

Page 91: ...PP06N 01 PREPARATION MAINTENANCE PP 1 53 Author Date 2001 SIENNA RM787U MAINTENANCE EQUIPMENT Mirror Brake hose Torque wrench...

Page 92: ...EQUIPMENT Torque wrench Bolt Length 35 mm 1 387 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...

Page 93: ...PP 50 PREPARATION SUPPLEMENTAL RESTRAINT SYSTEM 102 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09042 00020 Torx Socket T40 09082 00040 TOYOTA Electrical Tester 09082 00050 TOYOTA Electrical Tes...

Page 94: ...2001 SIENNA RM787U SUPPLEMENTAL RESTRAINT SYSTEM SST Special Service Tools 09082 00700 SRS Airbag Deployment Tool 09082 00750 Airbag Deployment Wire Sub harness No 3 SIDE AIRBAG ASSEMBLY 09082 00760...

Page 95: ...PP0PZ 01 PREPARATION SUSPENSION AND AXLE PP 35 87 Author Date 2001 SIENNA RM787U EQUIPMENT Dial indicator Torque wrench Drill...

Page 96: ...AXLE 88 Author Date 2001 SIENNA RM787U LUBRICANT Item Capacity Application Drive Shaft Outboard joint grease Color Black Inboard joint grease Color Gray Joint side Boot side 105 125 g 3 7 4 4 oz 120 0...

Page 97: ...PREPARATION SUSPENSION AND AXLE 86 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgf cm 09042 00010 Torx Socket T30 09905 00012 Snap Ring No 1 Expander 09905 00013 Sna...

Page 98: ...Replacer Front suspension 09240 00020 Wire Gauge Set Front drive shaft 09309 36010 Transmission Rear Bearing Replacer Front drive shaft 09309 37010 Transmission Bearing Replacer Rear suspension 09310...

Page 99: ...608 16042 Front Hub Bearing Adjusting Tool Front drive shaft 09608 02021 Bolt Nut 09608 02041 Retainer 09608 32010 Steering Knuckle Oil Seal Replacer Front axle Front suspension 09610 20012 Pitman Arm...

Page 100: ...on 09729 22031 Front Spring Upper Seat Holder Front suspension 09950 00020 Bearing Remover Front drive shaft 09950 4001 1 Puller B Set Rear suspension 09951 04010 Hanger 150 09952 04010 Slide Arm 0995...

Page 101: ...ND AXLE PP 33 85 Author Date 2001 SIENNA RM787U 09958 0401 1 Holder 09950 60010 Replacer Set 09951 00400 Replacer 40 Front axle 09951 00560 Replacer 56 Rear suspension 09950 70010 Handle Set Front axl...

Page 102: ...0 PREPARATION SFI 62 Author Date 2001 SIENNA RM787U EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector OBD II scan tool Soft brush Throttle body Sound scope Injector Torque wrench...

Page 103: ...I PP 9 61 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09040 0001 1 Hexagon Wrench Set 09082 00040 TOYOTA Electrical Tester 09200 00010 Engine Adjust Kit 09258 00030 Hose Plug Set Plug for the vac...

Page 104: ...09023 12700 Union Nut Wrench 17mm Fuel line flare nut 09268 41047 Injection Measuring Tool Set 09268 41 100 Clamp 90405 09015 No 1 Union 09268 45012 EFI Fuel Pressure Gauge 09817 1601 1 Back up Light...

Page 105: ...ION STEERING 98 Author Date 2001 SIENNA RM787U EQUIPMENT Belt tension gauge Drive belt Caliper gauge PS vane pump Calipers PS vane pump Dial indicator PS gear Feeler gauge PS vane pump Micrometer PS v...

Page 106: ...PP0AV 01 PREPARATION STEERING PP 47 99 Author Date 2001 SIENNA RM787U LUBRICANT Item Capacity Classification Power steering fluid Total 0 8 liters 0 8 US qts 0 7 lmp qts ATF DEXRON II or III...

Page 107: ...thor Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09025 00010 Torque Wrench 30 kgfcm PS vane pump PS gear 09042 00010 Torx Socket T30 Tilt steering column 09904 00010 Expander Set 09905 00012 Snap Ring N...

Page 108: ...PP0SK 01 PP 48 PREPARATION STEERING 100 Author Date 2001 SIENNA RM787U SSM Special Service Materials 08833 00080 Adhesive 1344 THREE BOND 1344 LOCTITE 242 or equivalent PS gear...

Page 109: ...Boot Clamping Tool PS gear 09527 2001 1 Rear Axle Shaft Bearing Remover PS gear 09612 00012 Rack Pinion Steering Rack Housing Stand PS gear 09612 07010 Main Shaft Retaining Ring Remover Replacer Tilt...

Page 110: ...Power Steering Pressure Gauge Set 09641 01010 Gauge Assy Power steering fluid 09641 01020 Attachment A Power steering fluid 09641 01030 Attachment B Power steering fluid 09910 00015 Puller Set 09911 0...

Page 111: ...54 05020 Claw No 2 Tilt steering column 09950 60010 Replacer Set 09951 00180 Replacer 18 PS gear 09951 00240 Replacer 24 PS gear 09951 00250 Replacer 25 PS gear 09951 00260 Replacer 26 PS gear 09951 0...

Page 112: ...00430 Replacer 43 PS gear 09952 06010 Adapter PS gear 09950 70010 Handle Set 09951 07100 Handle 100 PS vane pump 09951 07200 Handle 200 PS gear 09951 07360 Handle 360 PS gear 09960 10010 Variable Pin...

Page 113: ...uthor Date 2001 SIENNA RM787U EQUIPMENT Dial indicator Commutator Magnetic finger Steel ball Press Magnetic switch terminal kit Pull scale Brush spring Sandpaper Commutator Torque wrench V block Commu...

Page 114: ...PP078 02 PREPARATION STARTING PP 21 73 Author Date 2001 SIENNA RM787U RECOMMENDED TOOLS 09082 00040 TOYOTA Electrical Tester...

Page 115: ...e 2001 SIENNA RM787U STARTING SST Special Service Tools 09286 4601 1 Injection Pump Spline Shaft Puller Armature bearing 09810 38140 Starter Magnet Switch Nut Wrench 14 Terminal nut 09820 00030 Altern...

Page 116: ...IONING SERVICE DATA Refrigerant charge volume 1 050 50 g 37 03 1 76 oz Refrigerant charge volume 1 050 50 g 37 03 1 76 oz Idle speed Magnetic clutch not engaged 700 50 rpm Idle s eed Magnetic clutch n...

Page 117: ...55 48 in lbf Evaporator x Tube and accessory 5 4 55 48 in lbf Expansion valve x Liquid tube Evaporator side 14 140 10 Expansion valve x Liquid tube Tube side 22 225 16 COMPRESSOR AND MAGNETIC CLUTCH...

Page 118: ...e plate runout Max Torque converter clutch runout Max Torque converter clutch installation distance 0 20 mm 0 0079 in 0 30 mm 0 0118 in More than 13 7 mm 0 539 in Differential oil seal drive in depth...

Page 119: ...ift lever x Shift lever housing 12 120 9 Shift lever housing x Steering column assembly 12 120 9 Parking lock cable x Shift lever housing 4 4 45 39 in lbf Parking lock cable x Column upper bracket 2 2...

Page 120: ...ard indication km h Allowable range km h 20 17 24 40 38 46 60 57 5 67 80 77 88 100 96 109 120 115 130 140 134 151 5 160 153 173 TACHOMETER ON VEHICLE DC 13 5 V 25 C at 77 F Standard indication Allowab...

Page 121: ...anel 4 9 50 43 in lbf Door hinge x Door panel 25 260 19 Door hinge x Body 25 260 19 Outside handle x Door panel 5 5 56 49 in lbf Door lock cylinder x Door panel 5 5 56 49 in lbf Door check x Door pane...

Page 122: ...g assembly x Instrument panel 5 0 51 44 No 2 cowl bracket x Body 20 205 15 No 2 cowl bracket x Reinforcement 20 205 15 Steering wheel set nut 50 510 37 FRONT SEAT Seat adjuster x Body 37 380 27 Center...

Page 123: ...y x Reclining adjuster 43 440 32 Rear No 2 seat inner belt x Seat cushion frame 43 440 32 SEAT BELT Shoulder anchor x Adjustable anchor 43 440 32 Shoulder anchor x Body 43 440 32 Floor anchor x Body 4...

Page 124: ...ont brake pad thickness STD 11 0 mm 0 433 in Front brake pad thickness Minimum 1 0 mm 0 039 in Front brake disc thickness STD 28 0 mm 1 102 in Front brake disc thickness Minimum 26 0 mm 1 024 in Front...

Page 125: ...130 9 Brake pedal assembly x Reinforcement 20 200 15 Brake pedal x Pedal bracket 35 360 26 Pedal bracket x Cruise control ECU 5 0 51 41 in lbf Front disc brake caliper installation bolt 34 350 25 Fro...

Page 126: ...2 5 12 9 V Drive belt Tension New belt Used belt 175 5 lbf 115 20 lbf Generator Rated output Rotor coil resistance at 20 C 68 F Slip ring diameter STD Limit Brush exposed length STD Limit 12 V 100 A 2...

Page 127: ...d frame 5 4 55 48 in lbf Generator pulley x Rotor 110 5 1 125 81 Rectifier holder x Coil lead on rectifier end frame 2 9 30 26 in lbf Voltage regulator and brush holder x Rectifier end frame 2 0 20 18...

Page 128: ...80 84 C 176 183 F 10 0 mm 0 394 in or more Radiator cap Relief valve opening pressure STD Minimum 83 113 kPa 0 85 1 15 kgf cm2 12 1 16 4 psi 69 kPa 0 7 kgf cm2 10 0 psi Cooling fan Rotating amperage I...

Page 129: ...ock side cover 7 0 70 61 in lbf LH engine drain plug x Union on cylinder block 13 130 9 Water pump x Cylinder block 8 0 80 69 in lbf Water inlet x Water inlet housing 8 0 80 69 in lbf Water inlet pipe...

Page 130: ...ody 19 5 195 14 Exhaust manifold x Cylinder head 49 500 63 A F sensor x LH exhaust manifold 44 450 33 Front exhaust pipe x Exhaust manifold 62 630 46 Front exhaust pipe x Center exhaust pipe 56 570 41...

Page 131: ...w Terminals TE1 and E1 connected of DLC1 8 12 BTDC idle Idle speed 700 50 rpm Timing belt tensioner Protrusion from housing side 10 0 10 8 mm 0 394 0 425 in Cylinder head Warpage Maximum Valve seat R...

Page 132: ...amshaft gear backlash STD Maximum Camshaft gear spring end free distance 0 040 0 090 mm 0 0016 0 0035 in 0 12 mm 0 0047 in 0 035 0 072 mm 0 0014 0 0028 in 0 025 0 062 mm 0 0010 0 0024 in 0 10 mm 0 003...

Page 133: ...on STD Maximum Piston ring groove clearance No 1 No 2 Piston ring end gap STD No 1 No 2 Oil Maximum No 1 No 2 Oil 87 406 87 416 mm 3 4412 3 4416 in 87 453 87 467 mm 3 4430 3 4436 in 0 084 0 106 mm 0 0...

Page 134: ...m Thrust washer thickness Main journal oil clearance STD No 1 and No 4 No 2 and No 3 Maximum No 1 and No 4 No 2 and No 3 Main journal diameter Main bearing center wall thickness Reference TMC made Mar...

Page 135: ...6 Exhaust manifold stay x Exhaust manifold 20 200 14 Exhaust manifold stay x Transmission housing 20 200 14 PS pump bracket x RH cylinder head 43 440 32 Oil dipstick guide x LH cylinder head 8 80 69 i...

Page 136: ...bar x Drive belt adjusting bar bracket 18 185 13 Main bearing cap x Cylinder block 12 pointed head 1st 2nd 6 pointed head 22 Turn 90 27 225 Turn 90 275 16 Turn 90 20 Connecting rod cap x Connecting r...

Page 137: ...6 Spark plug Recommended spark plug DENSO NGK Correct electrode gap for new plug Maximum electrode gap for used plug SK20R11 IFR6A11 1 2 mm 0 047 in 1 0 1 1 mm 0 039 0 043 in Camshaft position sensor...

Page 138: ...1 SIENNA RM787U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Spark plug x Cylinder head 18 180 13 Ignition coil x Cylinder head 8 0 80 69 in lbf Camshaft position sensor x Cylinder head 8 0 8...

Page 139: ...speed at 3 000 rpm 29 kPa 0 3 kgf cm2 43 psi or more 294 539 kPa 3 0 5 5 kgf cm2 43 78 psi Oil pump Side clearance STD Maximum Body clearance STD Maximum Tip clearance STD Maximum 0 030 0 090 mm 0 00...

Page 140: ...il pan x Cylinder block 19 5 200 14 No 1 oil pan x Oil pump 10 mm head 12 mm head 8 0 19 5 80 200 69 in lbf 14 No 1 oil pan x Rear oil seal retainer 8 0 80 69 in lbf No 1 oil pan x Transaxle 37 2 380...

Page 141: ...SS03I 01 SS 4 SERVICE SPECIFICATIONS MAINTENANCE 119 Author Date 2001 SIENNA RM787U MAINTENANCE SERVICE DATA Front axle and suspension Ball joint vertical play Maximum 0 mm 0 in...

Page 142: ...ONS MAINTENANCE SS 5 120 Author Date 2001 SIENNA RM787U TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Front seat mount bolts 37 375 27 Front suspension member x Body 181 1 850 134 Rear axle be...

Page 143: ...TEM TORQUE SPECIFICATION Part tightened N m kgf cm ft lbf Steering wheel 34 350 25 Steering wheel pad 8 8 90 78 in lbf Front passenger airbag assembly x Instrument panel 20 200 14 Airbag sensor assemb...

Page 144: ...h difference 0 16 12 0 27 0 2 2 6 2 mm 0 10 0 08 in 1 5 mm 0 059 in or less Wheel angle Inside wheel 34 19 1 34 32 1 Wheel angle Inside wheel Outside wheel Reference 30 19 30 32 Rear wheel Camber Left...

Page 145: ...r bearing lock bolt 32 330 24 Suspension support x Body 80 820 59 Suspension support x Piston rod 49 500 36 ABS speed sensor set bolt 7 8 80 69 in lbf Flexible hose and ABS speed sensor wire harness x...

Page 146: ...position sensor Resistance Throttle valve fully closed VTA E2 Throttle valve fully open VTA E2 VC E2 0 2 6 3 k 2 0 10 2 k 2 5 5 9 k VSV for EVAP Resistance at 20 C 68 F 27 33 VSV for ACIS Resistance...

Page 147: ...egulator x Fuel pump bracket 2 0 20 17 in lbf Delivery pipe x Intake manifold 10 100 7 No 1 fuel pipe x Intake manifold 19 5 200 14 Fuel tank band x Body 39 400 29 Throttle body x Air intake chamber 1...

Page 148: ...een pump shaft and bushing STD 0 03 0 05 mm 0 0012 0 0020 in Oil clearance between pump shaft and bushing Maximum 0 07 mm 0 0028 in Vane plate height Minimum 8 6 mm 0 339 in Vane plate thickness Minim...

Page 149: ...18 Clamp plate set nut 7 8 80 69 in lbf Pump assembly set bolt A bolt 29 43 300 440 22 32 Pump assembly set bolt B bolt 43 440 32 Oil pressure switch x Union bolt 21 210 15 Union bolt x Pressure feed...

Page 150: ...ring installed load STD Minimum Commutator Diameter STD Minimum Undercut depth STD Minimum Circle runout Maximum Magnetic switch Contact plate for wear Maximum 12 V 1 4 kW 90 A or less at 11 5 V 3 000...

Page 151: ...37 380 27 End cover x Field frame 1 5 15 13 in lbf Starter housing x Magnetic switch 5 9 60 52 in lbf Field frame x Armature assembly 5 9 60 52 in lbf Lead wire x Terminal C of starter 5 9 60 52 in lb...

Page 152: ...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 1 116 Author Date 2001 SI...

Page 153: ...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 3 118 Author Date 2001 SIENNA RM787U HOW TO DETERMINE NUT STRENGTH HINT...

Page 154: ...175 360 670 1 050 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 l...

Page 155: ...es power to each ABS solenoid After the ignition switch is turned ON if the initial check is OK the relay goes on DTC No DTC Detecting Condition Trouble Area 11 With IG1 terminal voltage at 9 5V 18 5V...

Page 156: ...ATION Disconnect the ABS actuator connector CHECK Measure the voltage between terminals BM 24 GND 8 23 and terminals BS 9 GND 8 23 ABS actuator harness side connector OK Voltage 10 14 V NG Check and r...

Page 157: ...N and operates the ABS pump motor DTC No DTC Detecting Condition Trouble Area 13 Detection of any conditions in 1 and 2 1 When pump motor relay is ON relay contact is OFF 1 for 0 2 sec or longer 2 Whe...

Page 158: ...ATION Disconnect the ABS actuator connector CHECK Measure the voltage between terminals BM 24 GND 8 23 and terminals BS 9 GND 8 23 ABS actuator harness side connector OK Voltage 10 14 V NG Check and r...

Page 159: ...CUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force DTC No DTC Detecting Condition...

Page 160: ...NNA RM787U INSPECTION PROCEDURE 1 Check the DTC once more PREPARATION a Clear the DTC See page DI 220 b Turn the ignition switch OFF CHECK Turn the ignition switch ON and check that the same DTC is st...

Page 161: ...s used by the ECU to detect the speed of each wheel DTC No DTC Detecting Condition Trouble Area 31 32 33 34 Detection of any of conditions from 1 through 4 1 With vehicle speed at 10 km h or more sens...

Page 162: ...8 IK5 IK5 BR IK5 3 7 4 Y BR Y 22 Shielded Shielded Shielded L 2 1 P 20 Shielded Shielded ABS Speed Sensor Rear RH 2 1 BA2 IC2 W W 18 B B Shielded BA2 BA2 BA2 BA2 IC2 IC2 R R 2 10 9 17 ABS Speed Senso...

Page 163: ...of speed sensor connector and body ground OK Resistance 1 M or higher Rear PREPARATION a Remove the seat cushion and side seatback b Make sure that there is no looseness at the connector lock part an...

Page 164: ...sensor and ECU See page IN 31 NG Repair or replace harness or connector OK 3 Check front speed sensor installation CHECK Check the speed sensor installation OK The installation bolt is tightened prop...

Page 165: ...dentified in the waveform on the oscillo scope error signals are generated due to the speed sen sor rotor s scratches looseness or foreign matter depos ited on it NG Replace rear axle hub OK 5 Check f...

Page 166: ...ng teeth or foreign objects PREPARATION Remove the front speed sensor See page BR 49 CHECK Check the sensor tip OK No scratches or foreign objects on the sensor tip HINT If foreign matter including th...

Page 167: ...on Trouble Area 41 Detection of any of conditions from 1 through 3 1 With vehicle speed at 3 km h or more IG1 or BS termi nal voltage is 9 5V or below for 10 sec or longer 2 With IG1 terminal voltage...

Page 168: ...ontrol ECU EA 1 B L F8 Fusible Link Block 2D 2L 2 2 W 1K W L 4 2 W L 2 60A ABS Driver Side J B No 1 1K 1A 6 Engine Room R B No 2 2B 2L 2L 6 W G 9 Engine Room J B No 2 2J 2F 2C 5 10 W B W B W B W B 8 E...

Page 169: ...IG fuse PREPARATION Remove ECU IG fuse from Instrument Panel J B CHECK Check continuity of ECU IG fuse OK Continuity NG Check for short in circuit all the harness and components connected to ECU IG f...

Page 170: ...n terminals IG1 15 GND 8 23 of ABS actuator harness side connector OK Voltage 10 14 V OK Check or replace ABS actuator assembly NG 4 Check continuity between terminals GND of ABS actuator connector an...

Page 171: ...6 W B Stop Light RH R10 Stop Light LH R9 W B G W W B 1 2 5 2 5 2 BN BM BK A A A A A W B W B W B 4 4 2 4 2 B L Driver Side J B No 1 G W J B No 3 W B W B 3 BD1 BB1 BB1 BD1 BD2 BD2 DIAGNOSTICS ANTI LOCK...

Page 172: ...rminal STP of ABS actuator and body ground PREPARATION Disconnect ABS actuator connector CHECK Measure the voltage between terminal STP 5 of ABS actuator harness side connector and body ground when br...

Page 173: ...2 2J 2F 2C W B W B W B 5 10 EA IG B G 2 W L 2 60A ABS 2 1 2B Engine Room J B No 2 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM DI 245 399 Author Date 2001 SIENNA RM787U DTC 51 ABS Pump Motor Lock CIRCUIT DESCR...

Page 174: ...RM787U INSPECTION PROCEDURE 1 Check the DTC once more PREPARATION a Clear the DTC See page DI 220 b Turn the ignition switch OFF CHECK Turn the ignition switch ON and check if the same DTC is stored i...

Page 175: ...B WA B Combination Meter Driver Side J B No 1 Junction Connector IG1 AM1 DI 250 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 404 Author Date 2001 SIENNA RM787U ABS Warning Light Circuit CIRCUIT DESCRIPTION If...

Page 176: ...I 247 1 Check operation of the ABS warning light PREPARATION a Turn the ignition switch OFF b Disconnect the connector from the ABS actuator c Turn the ignition switch ON CHECK Check the ABS warning l...

Page 177: ...ions in 1 2 3 and 4 1 Skid control ECU internal malfunction is detected 2 IG1 terminal voltage is 7 V or below 3 ECU connector is not connected 4 There is a malfunction in ABS warning light circuit Ba...

Page 178: ...nition switch ON b Measure voltage between terminals IG1 15 GND 8 23 of ABS actuator harness side connector OK Voltage 10 14 V NG Check for open and short circuit in harness and connector between ECU...

Page 179: ...wire connect terminal WA 13 and GND1 8 of ABS actuator connector b Turn the ignition switch ON OK ABS warning light goes off OK Check and replace ABS actuator assembly NG 7 Check for open circuit in...

Page 180: ...F13950 DI 256 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 410 Author Date 2001 SIENNA RM787U Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines DI04B 16...

Page 181: ...E IH2 E1 Tc 5 13 3 8 A5 BR W BR W BR W DI 252 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 406 Author Date 2001 SIENNA RM787U Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Tc and E1 of DLC1 or Tc...

Page 182: ...b Measure voltage between terminals Tc and E1 of DLC1 Tc and CG of DLC3 OK Voltage 10 14 V OK If ABS warning light does not blink even after Tc and E1 or Tc and CG are connected the ECU may be defect...

Page 183: ...detects abnormalities which cannot be detected with the DTC check in the speed sensor signal Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check WIRING DIAGRAM INSPEC...

Page 184: ...9 Author Date 2001 SIENNA RM787U 2 Check for open and short circuit in harness and connector between ABS actua tor and DLC1 DLC1 and body ground See page IN 31 NG Repair or replace harness or connecto...

Page 185: ...inuous Intermittent times a day Remains ON Does not Light Up DTC Check 1st Time 2nd Time Normal Code Malfunction Code Code Normal Code Malfunction Code Code Symptoms km miles ABS does not operate ABS...

Page 186: ...rcuit ABS actuator 22 DI 231 Left front solenoid valve faulty Left front circuit ABS actuator 23 DI 231 Right rear solenoid valve faulty Right rear circuit ABS actuator 24 DI 231 Left rear solenoid va...

Page 187: ...ction P DI 227 DI 254 DTC Chart P DI 223 Malfunction code Problem Symptoms Table P DI 226 Check for Fluid Leakage P DI 256 Identification of Problem Normal code Repair Confirmation Test End 1 2 3 4 5...

Page 188: ...Actuator with Skid Control ECU Front Speed Sensor Rear Speed Sensor with Rear Axle Hub Stop Light Switch Sensor Rotor Front Speed Sensor DLC1 DLC3 DI 224 DIAGNOSTICS ANTI LOCK BRAKE SYSTEM 378 Author...

Page 189: ...BS warning light circuit See page DI 250 b Check the DTC 1 Using SST connect terminals Tc and E1 of DLC1 or Tc and CG of DLC3 SST 09843 18020 or 09843 18040 2 Turn the ignition switch ON 3 Read the DT...

Page 190: ...nition switch OFF b Using SST connect terminals Ts and E1 of DLC1 SST 09843 18020 c Start the engine d Check that the ABS warning light blinks HINT If the ABS warning light does not blink inspect the...

Page 191: ...speed sensor rotor Sensor installation 72 Low output voltage of left front speed sensor Left front speed sensor Left front speed sensor rotor Sensor installation 73 Low output voltage of right rear s...

Page 192: ...uit 6 Hydraulic circuit for leakage DI 220 DI 239 DI 233 DI 256 ABS does not operate efficiently Only when 1 5 are all normal and the problem is still occurring replace the skid control ECU 1 Check th...

Page 193: ...14 IG1 15 GND 8 23 B R W B IG switch ON 10 14 WA 13 GND 8 23 GR W B IG switch ON ABS warning light ON 3 5 STP 5 GND 8 23 G W W B Stop light switch OFF Below 1 0 STP 5 GND 8 23 G W W B Stop light switc...

Page 194: ...Fusible Link Block W L B Y Driver Side J B No 1 ABS Warning Light Driver Side J B No 1 1 B L 100A INP W C10 9 V14 23 I12 Ignition Switch R L GR D D J18 J C GR J17 J C A A Combination Meter 10A GAUGE D...

Page 195: ...page DI 334 1 Check operation of the ABS warning light PREPARATION a Turn the ignition switch OFF b Disconnect the connector from the skid control ECU c Turn the ignition switch ON CHECK Check the ABS...

Page 196: ...10A GAUGE DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 331 485 Author Date 2001 SIENNA RM787U DTC Always ON Malfunction in ECU VSC Warning Light Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Cond...

Page 197: ...d by the output code NO 2 Check that the ECU connectors are securely connected to the ECU NO Connect the connector to the ECU YES 3 Check battery positive voltage CHECK Check the battery positive volt...

Page 198: ...er CHECK Check that ON and OFF of the VSC warning light can be shown on the combination meter by the TOYOTA hand held tester In case of not using the TOYOTA hand held tester PREPARATION a Turn the ign...

Page 199: ...327 481 Author Date 2001 SIENNA RM787U DTC Always ON Malfunction in ECU ABS Warning Light Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area Always ON Either of the following 1 2...

Page 200: ...ected to the ECU NO Connect the connector to the ECU YES 3 Check voltage between terminals IG1 56 and GND 29 83 of skid control ECU PREPARATION Disconnect the connector from the skid control ECU CHECK...

Page 201: ...er 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...

Page 202: ...g light See the combination meter troubleshooting on page BE 2 NG Repair or replace bulb or combination meter OK 8 Check for open circuit in harness and connector between combination meter and skid co...

Page 203: ...40A AM1 10A GAUGE J18 J C 8 9 1 W B J C J17 J C J8 J C E BRL EBDW EBDW PKB LBL PKB LBL LVL2 BRL PKB2 T10 T10 T10 T10 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 339 493 Author Date 2001 SIENNA RM7...

Page 204: ...or replace parking brake switch circuit OK 2 Check brake fluid level warning switch circuit See page BE 48 NG Repair or replace brake fluid level warning switch circuit OK 3 Is DTC output YES Repair...

Page 205: ...r OK 7 Check active lamp relay In case in which the BRAKE warning light does not light up PREPARATION a Turn the ignition switch OFF b Disconnect the connector from the skid control ECU c Turn the ign...

Page 206: ...ble Area C0200 31 C0205 32 C0210 33 C0215 34 When any of the following 1 to 3 is detected 1 Vehicle speed is more than 40 km h 25 mph pulses are not input for 0 01 sec 2 After the initial start or res...

Page 207: ...7 68 69 BR Y IK5 IK5 IK5 7 4 3 L P W B R G W B R G Shielded Shielded Shielded IC2 BA2 IC2 BA2 IC2 BA2 IC2 BA2 BA2 2 1 2 1 8 9 2 6 10 7 2 10 3 11 9 BR BR W BR W Shielded ABS Speed Sensor Front LH ABS S...

Page 208: ...OYOTA 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 DATALIST mode on the TOYOTA hand held tester CHECK Check that there is...

Page 209: ...speed sensor connector and body ground OK Resistance 1 M or higher Rear PREPARATION a Remove the seat cushion and seatback b Make sure that there is no looseness at the connector lock part and connec...

Page 210: ...ensor and skid control ECU See page IN 31 NG Repair or replace harness or connector OK 4 Check front speed sensor installation CHECK Check the speed sensor installation OK The installation bolt is tig...

Page 211: ...se is identified in the waveform on the oscillo scope error signals are generated due to the speed sen sor rotor s scratches looseness or foreign matter depos ited on it NG Replace rear axle hub OK 6...

Page 212: ...s missing teeth or foreign objects PREPARATION Remove the front speed sensor See page BR 49 CHECK Check the sensor tip OK No scratches or foreign objects on the sensor tip HINT If foreign matter inclu...

Page 213: ...VSC actuator SFRR or SFRH circuit C0236 22 Open or short in SFLR or SFLH circuit ABS VSC actuator SFLR or SFLH circuit C0246 23 Open or short in SRRR or SRRH circuit ABS VSC actuator SRRR or SRRH circ...

Page 214: ...C2 60 V14 58 81 55 53 80 61 59 54 52 49 50 G O B W W G Y B B O GR R Y G LG B L Y LG V W W L 2 V8 15 7 12 1 10 3 9 4 8 11 14 13 Y ED1 5 ABS VSC Actuator W L 2 ALT 1 2 W B ED 7 SFLH SFLR SFRH SFRR SRLH...

Page 215: ...ity between terminals 2 and each of 1 3 4 7 8 9 10 11 12 13 14 15 of ABS VSC actuator OK Continuity NG Replace ABS VSC actuator OK 2 Check for open and short circuit in harness and connector between s...

Page 216: ...2 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 285 439 Author Date 2001 SIENNA RM787U DTC C0273 13 ABS MTR Relay Circuit CIRCUIT DESCRIPTION The ABS MTR relay supplies power to the ABS VSC actuator...

Page 217: ...ION 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 CHE...

Page 218: ...om engine room R B No 7 CHECK Measure the voltage between terminal 1 of engine room R B No 7 for ABS MTR relay and body ground OK Voltage 10 14 V NG Check and repair harness or connector OK 4 Check AB...

Page 219: ...ontrol ECU CHECK Check continuity between terminal BM 2 of engine room R B No 7 and terminal MT 82 of skid control ECU harness side connector OK Continuity NG Repair or replace harness OK 6 Check for...

Page 220: ...id After the ignition switch is turned ON if the initial check is OK the relay goes on DTC No DTC Detecting Condition Trouble Area C0278 11 Detection of any conditions from 1 through 2 1 3 or more sol...

Page 221: ...C2 60 V14 58 81 55 53 80 61 59 54 52 49 50 G O B W W G Y B B O GR R Y G LG B L Y LG V W W L 2 V8 15 7 12 1 10 3 9 4 8 11 14 13 Y ED1 5 ABS VSC Actuator W L 2 ALT 1 2 W B ED 7 SFLH SFLR SFRH SFRR SRLH...

Page 222: ...K Voltage 10 14 V NG Check and repair the charging system See page CH 2 OK 2 Check voltage between terminals 1 and 2 of engine room R B No 8 for ABS SOL relay PREPARATION Remove the ABS SOL relay from...

Page 223: ...relay CHECK Check continuity between following terminals of ABS SOL relay OK Terminals 4 and 6 Continuity Reference value 80 Terminals 2 and 3 Continuity Terminals 1 and 3 Open CHECK a Apply battery p...

Page 224: ...ach terminals 49 50 52 53 54 55 58 59 60 61 80 and 81 of ECU harness side connector OK Continuity HINT Resistance of each solenoid coil SFLH 60 SRRH 61 SFRH 81 SMC1 49 SMC2 50 SRLH 53 8 9 1 at 20 C 68...

Page 225: ...Deceleration sensor is combined with yaw rate sensor DTC No DTC Detecting Condition Trouble Area C0365 43 Detection of any of conditions from 1 through 4 1 The sensor signal is out of range less than...

Page 226: ...hat the deceleration value of the deceleration sensor displayed on the TOYOTA hand held tester is changing when tilting the vehicle OK Deceleration value must be changing OK Check and replace skid con...

Page 227: ...YSTEM 450 Author Date 2001 SIENNA RM787U 4 Check for open or short circuit in harness and connector between deceleration sensor and skid control ECU See page IN 31 NG Repair or replace harness and con...

Page 228: ...371 55 Yaw Rate Sensor Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area C0371 55 Detection of any of conditions from 1 through 4 1 The voltage of sensor signal is out of range 2...

Page 229: ...DATALIST mode on the TOYOTA hand held tester CHECK Check that the yaw rate value of the yaw rate sensor displayed on the TOYOTA hand held tester is changing Place the yaw rate sensor vertically to th...

Page 230: ...k yaw rate sensor CHECK a Turn the ignition switch ON b Measure the voltage between terminals IGA 3 and GYW2 1 YAW2 4 and GYW2 1 of the yaw rate sensor with connector still connected OK Terminals 3 an...

Page 231: ...luid Level Warning Switch Cir cuit CIRCUIT DESCRIPTION The brake fluid level warning switch sends appropriate signals to the ECU when the brake fluid level is low ered HINT Depressing the parking brak...

Page 232: ...id in the reservoir NG Check for fluid leakage repair brake line and add fluid OK 2 Check brake fluid level warning switch See page BE 48 NG Replace brake fluid level warning switch OK 3 Check for ope...

Page 233: ...TION DTC No DTC Detecting Condition Trouble Area C1208 54 Detection of any of conditions 1 through 7 1 When the condition that ECU terminal IG1 voltage is 9 8 V or more and does not receive data from...

Page 234: ...nd held tester CHECK Check that the steering wheel turning angle value of the steering angle sensor displayed on the TOYOTA hand held tester is appropriate when turning the steering wheel OK Steering...

Page 235: ...g angle sensor See page SR 1 1 OK 4 Check for open and short circuit in harness and connector between steering angle sensor translate ECU and skid control ECU See page IN 31 NG Repair or replace harne...

Page 236: ...ABS WITH EBD BA TRAC VSC SYSTEM DI 305 459 Author Date 2001 SIENNA RM787U 7 Replace the ECU and check whether or not the trouble occurs again YES Replace steering angle sensor NO Check and replace ski...

Page 237: ...h or less 2 When the ignition switch is ON the slip difference be tween the reference wheel and any other wheels is 6 or more vehicle speed 100 km h 62 mph or more 3 Continuous ABS control for 60 sec...

Page 238: ...Author Date 2001 SIENNA RM787U 4 Check for open and short circuit in harness and connector between front speed sensors rear speed sensors and skid control ECU See page IN 31 NG Repair or replace harn...

Page 239: ...TRAC VSC SYSTEM 462 Author Date 2001 SIENNA RM787U DTC C1241 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU hence the brake actuators DTC No DTC Detecting Conditi...

Page 240: ...U IG fuse PREPARATION Remove the ECU IG fuse from the driver side J B No 1 CHECK Check continuity of the ECU IG fuse OK Continuity NG Check for short circuit in all the harness and components connecte...

Page 241: ...voltage between terminals 56 and 29 83 of skid control ECU harness side connector OK Voltage 10 14 V OK Check and replace skid control ECU NG 4 Check continuity between terminals GND 29 83 of skid co...

Page 242: ...Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area C1246 53 When any of the following 1 through 3 is detected 1 The voltage of sensor signal is out of range less than 0 25 V more...

Page 243: ...e sensor displayed on the TOYOTA hand held tester is changing when depressing the brake pedal OK Brake fluid pressure value must be changing Voltage 0 25 4 75 V OK Go to step 4 NG 2 Check master cylin...

Page 244: ...8 of skid control ECU and body ground when the brake pedal is depressed and released PREPARATION Disconnect the connector from the skid control ECU CHECK Measure the voltage between terminal 48 of ski...

Page 245: ...I 314 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM 468 Author Date 2001 SIENNA RM787U DTC C1249 58 Stop Light Switch Circuit CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area C1249 58 Whe...

Page 246: ...8 of skid control ECU and body ground PREPARATION Disconnect the connector from the skid control ECU CHECK Measure the voltage between terminal 48 of skid control ECU harness side connector and body g...

Page 247: ...ng Condition Trouble Area C1300 62 Skid control ECU internal malfunction is detected Skid control ECU INSPECTION PROCEDURE 1 Check the DTC for the ABS and VSC See page DI 259 1 Repair ABS and VSC cont...

Page 248: ...C SYSTEM DI 317 471 Author Date 2001 SIENNA RM787U DTC C1350 51 ABS VSC Actuator Pump Motor Fail ure CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area C1350 51 When any of the following...

Page 249: ...ctuator CHECK Connect positive lead to terminal 6 and negative lead to terminal 5 of the ABS VSC actuator check that the pump mo tor is operated OK The running sound of the pump motor should be heard...

Page 250: ...s used to send TRAC VSC control information from skid control ECU to the translate ECU VSC VSC engine control information and steering angle information from translate ECU to skid control ECU DTC No D...

Page 251: ...REFERENCE INSPECTION USING OSCILLOSCOPE PREPARATION a Remove the translate ECU b Connect the oscilloscope to the terminal VSC 4 and GND 14 of the translate ECU harness side connector CHECK Start the...

Page 252: ...etecting Condition Trouble Area 44 When either of the following 1 or 2 is detected 1 The vehicle speed is 30 km h 19 mph or more and open or short condition of the engine revolution signal under the n...

Page 253: ...heck voltage between terminal NEO 13 of translate ECU and body ground PREPARATION Remove the translate ECU with connectors still connected CHECK a Turn the ignition switch ON b Measure the voltage bet...

Page 254: ...o the translate ECU ENG ENG DTC No DTC Detecting Condition Trouble Area 53 When any of the following 1 through 3 is detected 1 IG1 voltage is 8 5 V or more and the condition that data can not be sent...

Page 255: ...TION a Remove the translate ECU b Connect the oscilloscope to each of the terminals ENG or TRC and GND of the translate ECU harness side con nector CHECK Start the engine and check the signal waveform...

Page 256: ...F13417 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 355 509 Author Date 2001 SIENNA RM787U Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines DI6OQ 02...

Page 257: ...Condition Trouble Area Non Code Translate ECU internal malfunction is detected Translate ECU INSPECTION PROCEDURE 1 Check the BRAKE warning light circuit See page DI 339 NG Repair or replace the BRAK...

Page 258: ...tion is other than P and N range input volt age is 8 V or more 4 The shift position is PN or rev and D range input voltage is 8 V or more Brake fluid level Brake fluid level warning switch circuit Ste...

Page 259: ...e J B No 1 SLIP Driver Side J B No 1 1 B L 100A INP W C9 9 V14 31 I12 Ignition Switch L B GR D D J18 J C GR J17 J C A A Combination Meter Indicator Light DI 342 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SY...

Page 260: ...r 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 and OFF of the SLIP ind...

Page 261: ...Date 2001 SIENNA RM787U 4 Check for open and short circuit in harness and connector between skid control ECU and SLIP indicator light IG switch and SLIP indicator light See page IN 31 NG Repair or rep...

Page 262: ...6 J C J8 J C BR 13 5 F CG TC EI TC DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 351 505 Author Date 2001 SIENNA RM787U Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Tc and E1 of DLC1...

Page 263: ...on switch ON b Measure voltage between terminals Tc and E1 of DLC1 or Tc and CG of DLC3 OK Voltage 10 14 V OK If each warning light does not blink even after Tc and E1 or Tc and CG are connected the E...

Page 264: ...TS R Y R Y R Y DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 353 507 Author Date 2001 SIENNA RM787U Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormality in the speed...

Page 265: ...sure the voltage between terminals Ts and E1 of DLC1 or Ts and CG of DLC3 OK Voltage 10 14 V OK If ABS warning light does not blink even after Ts and E1 or Ts and CG are connected the ECU may be defec...

Page 266: ...er Circuit CIRCUIT DESCRIPTION The VSC buzzer sounds during VSC operation WIRING DIAGRAM INSPECTION PROCEDURE HINT Start the inspection from step 1 in case of using the TOYOTA hand held tester and sta...

Page 267: ...PARATION Remove the VSC buzzer with connectors still connected CHECK a Turn the ignition switch ON b Measure voltage between terminal 1 of VSC buzzer and body ground OK Voltage 10 14 V NG Repair or re...

Page 268: ...VSC SYSTEM 504 Author Date 2001 SIENNA RM787U 5 Check for open and short circuit in harness and connector between skid control ECU and VSC buzzer See page IN 31 NG Repair or replace harness or connect...

Page 269: ...AC OFF Switch 10A GAUGE GR DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM DI 345 499 Author Date 2001 SIENNA RM787U TRAC OFF Indicator Light TRAC OFF Switch Circuit CIRCUIT DESCRIPTION This is the TRAC c...

Page 270: ...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 and OFF of the TRAC OFF indicator light can be shown on the comb...

Page 271: ...G Repair or replace harness or connector OK 4 Check TRAC OFF indicator light See combination meter troubleshooting on page BE 2 NG Repair or replace bulb or combination meter OK 5 Check for open and s...

Page 272: ...er Side J B No 1 1 B L 100A INP W C9 9 V14 12 I12 Ignition Switch GR R GR D D J18 J C GR J17 J C A A Combination Meter 10A GAUGE DI 336 DIAGNOSTICS ABS WITH EBD BA TRAC VSC SYSTEM 490 Author Date 2001...

Page 273: ...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...

Page 274: ...r Date 2001 SIENNA RM787U 4 Check for open and short circuit in harness and connector between skid control ECU and VSC warning light IG switch and VSC warning light See page IN 31 NG Repair or replace...

Page 275: ...rate efficiently Does not Light Up ABS BA TRAC VSC Check Sheet BA does not operate VSC does not operate Wheels sideslip at the time of sharp turning ABS Warning Light Abnormal Remains ON Does not Ligh...

Page 276: ...Open or short circuit in ABS VSC actuator solenoid circuit SFR circuit ABS VSC actuator SFRR or SFRH circuit C0236 22 DI 282 Open or short circuit in ABS VSC actuator solenoid circuit SFL circuit ABS...

Page 277: ...level warning switch Brake fluid level warning switch circuit C1208 54 DI 302 Malfunction in steering angle sensor Steering angle sensor Steering angle sensor circuit Translate ECU C1225 25 DI 282 Op...

Page 278: ...SC or VSC circuit Translate ECU Skid control ECU 44 DI 321 Open or short circuit in NEO circuit NEO circuit ECM Translate ECU 53 DI 323 Malfunction in communication with the ECM TRC or TRC circuit ENG...

Page 279: ...roblem Normal code Repair Confirmation Test End 1 2 3 4 5 6 7 8 9 10 11 Fail safe function When a failure occurs in the ABS BA TRAC VSC system the respective warning light ABS VSC is lit and the opera...

Page 280: ...Master Cylinder Pressure Sensor Stop Light Switch Translate ECU Front Speed Sensor Sensor Rotor Rear Speed Sensor with Rear Axle Hub DLC3 Steering Angle Sensor Yaw Rate Sensor Including Deceleration...

Page 281: ...for the ABS warning light circuit VSC warn ing light circuit TRAC OFF indicator light circuit BRAKE warning light circuit or SLIP indicator light circuit Trouble Area See page ABS warning light circui...

Page 282: ...splayed 1st c In case of not using TOYOTA hand held tester Check the DTC of translate ECU 1 Release the parking brake pedal 2 Check the brake fluid level 3 Using SST connect terminals Tc and E1 of DLC...

Page 283: ...using TOYOTA hand held tester Clear the DTC 1 Using SST connect terminals Tc and E1 of DLC1 or Tc and CG of DLC3 SST 09843 18020 or 09843 18040 2 Turn the ignition switch ON 3 Clear the DTC stored in...

Page 284: ...mph for several seconds check that the ABS warn ing light comes off HINT The sensor check may not be completed if the front wheels are spun or the steering wheel is steered during this check 6 Stop t...

Page 285: ...tallation Left rear speed sensor rotor C1275 75 Abnormal change in output signal of right front speed sen sor Right front speed sensor rotor C1276 76 Abnormal change in output signal of left front spe...

Page 286: ...angle sensor TRAC OFF switch circuit VSC buzzer circuit or skid control ECU so check the DTC and repair or replace them 4 DECELERATION SENSOR CHECK a Connect IGA terminal to the battery positive term...

Page 287: ...o be normal 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 VSC actuator with a TOYOTA hand...

Page 288: ...l 1 BRAKE warning light circuit 2 Skid control ECU DI 339 TRAC OFF indicator light abnormal If the symptoms still occur even after the following circuits in suspect areas are inspected and proved to b...

Page 289: ...F 10 14 VSCW V14 12 GND V14 GR R BR IG switch ON VSC warning light ON Below 2 0 VSCW V14 12 GND V14 83 29 GR R BR IG switch ON VSC warning light OFF 10 14 PKB V14 16 GND V14 Y G BR IG switch ON parkin...

Page 290: ...F 10 14 SRC2 V14 52 GND V14 83 29 L Y BR IG switch ON ABS warning light OFF 10 14 SRLH V14 53 GND V14 83 29 Y B BR IG switch ON ABS warning light OFF 10 14 SRC1 V14 54 GND V14 83 29 LG B BR IG switch...

Page 291: ...Author Date 2001 SIENNA RM787U SRLR V14 80 GND V14 83 29 B O BR IG switch ON ABS warning light OFF 10 14 SFRH V14 81 GND V14 83 29 B W BR IG switch ON ABS warning light OFF 10 14 MT V14 82 GND V14 83...

Page 292: ...ch ON Below 1 5 LVL2 T10 11 GND T10 14 R W BR IG switch ON fluid level switch OFF 4 8 D T10 12 GND T10 14 B R BR IG switch ON shift lever is in D range 8 14 D T10 12 GND T10 14 B R BR IG switch ON shi...

Page 293: ...B L B BR ED 1 2 3 4 5 8 7 R L A33 Air Vent Mode Control Servomotor DI 744 DIAGNOSTICS AIR CONDITIONING SYSTEM 898 Author Date 2001 SIENNA RM787U Air Outlet Control Servomotor Circuit CIRCUIT DESCRIPT...

Page 294: ...flow mode OK The mode changes with the change in the tempera ture display as shown in the table OK Proceed to next circuit inspection shown on problem symptoms table See page DI 697 NG 2 Check air out...

Page 295: ...Check harness and connector between A C control assembly and air outlet con trol servomotor air outlet control servomotor and battery air outlet control ser vomotor and body ground See page IN 31 NG R...

Page 296: ...Motor Y G 14 A24 P P P B II2 17 2 3 1 4 BLWR BMC GND B L W L R II4 II4 From Rear A C Relay 2 W B BO DI 768 DIAGNOSTICS AIR CONDITIONING SYSTEM 922 Author Date 2001 SIENNA RM787U Blower Motor Circuit R...

Page 297: ...bly with connector still con nected CHECK a Turn ignition switch to ON b Operate blower motor c Measure voltage between terminal RLWH of A C control assembly and body ground OK Voltage 1 3 V OK Go to...

Page 298: ...C control assembly with connector still con nected CHECK a Turn ignition switch to ON b Operate rear A C blower motor c Measure voltage between terminal VMH of A C control assembly and body ground wh...

Page 299: ...d to terminal 2 b Check the test bulb lights up when another positive lead is connected to terminal 4 through a 12 V 3 4 W test bulb OK Test bulb lights up CHECK Measure resistance between terminals 2...

Page 300: ...L Y P B IE2 6 2 3 1 4 BLWC VMC GND B L IE1 IK2 From Rear Rr CLR Relay 3 W B BM 2 W G W G W G P B IE2 L Y DI 772 DIAGNOSTICS AIR CONDITIONING SYSTEM 926 Author Date 2001 SIENNA RM787U Blower Motor Cir...

Page 301: ...bly with connector still con nected CHECK a Turn ignition switch to ON b Operate blower motor c Measure voltage between terminal BLWC of A C control assembly and body ground OK Voltage 1 3 V OK Go to...

Page 302: ...C control assembly with connector still con nected CHECK a Turn ignition switch to ON b Operate rear A C blower motor c Measure voltage between terminal VMC of A C control assembly and body ground wh...

Page 303: ...to terminal 2 b Check the test bulb lights up when another positive lead is connected to terminal 4 through a 12 V 3 4 W test bulb OK Test bulb lights up CHECK Measure resistance between terminals 2 a...

Page 304: ...NING SYSTEM DI 765 919 Author Date 2001 SIENNA RM787U Blower Motor Circuit Front A C CIRCUIT DESCRIPTION The blower motor is operated by signals from the A C control assembly Blower motor speed signal...

Page 305: ...ower mo tor connector negative lead to terminal 1 OK Blower motor operates smoothly NG Replace blower motor OK 2 Check harness and connector between battery and blower motor linear control ler blower...

Page 306: ...DIAGNOSTICS AIR CONDITIONING SYSTEM DI 767 921 Author Date 2001 SIENNA RM787U 4 Check A C control assembly See page IN 31 NG Replace A C control assembly OK Replace blower motor linear controller...

Page 307: ...Power Source Circuit CIRCUIT DESCRIPTION This is the back up power source for the A C control assembly Power is supplied even when the ignition switch is off and is used for diagnostic trouble code m...

Page 308: ...nd body ground PREPARATION Remove the A C control assembly with connector still con nected CHECK Measure voltage between terminal B of A C control assembly connector and body ground OK Voltage 10 14 V...

Page 309: ...e 1 1H 2 1I E7 6 E7 7 ACMG ACI ECM IG FL Block 2 1 4 3 3 1 2 ALT Engine Room J B J B No 3 Driver Side J B Engine Room R B No 5 Engine Room J B Driver Side J B W L B 3 DI 776 DIAGNOSTICS AIR CONDITIONI...

Page 310: ...y ground when A C switch is On and OFF OK A C switch Voltage ON 10 14 V OFF 0 V NG Go to step 5 OK 2 Check magnetic clutch relay PREPARATION Remove magnetic clutch relay from engine room J B CHECK Che...

Page 311: ...arness and connector between magnetic clutch relay and ECM A C compressor and body ground See page IN 31 NG Repair or replace harness or connector OK Proceed to next circuit inspection shown on proble...

Page 312: ...ontrol assem bly connector and body ground when magnetic clutch is ON and OFF by A C switch OK Magnetic clutch Voltage ON Below 1 V OFF 10 14 V NG Check and replace A C control assembly OK 7 Check vol...

Page 313: ...ENNA RM787U 8 Check harness and connector between magnetic clutch relay and A C control assembly compressor and body ground See page IN 21 NG Repair or replace harness or connector OK Proceed to next...

Page 314: ...mperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cabin and sends the appropriate signals to the A C control assembly DTC No Detection Item Trouble Area 11 Op...

Page 315: ...ectors still connected CHECK a Turn ignition switch ON b Measure voltage between terminals TR and SG of A C control assembly connector at each temperature OK Voltage at 25 C 77 F 1 8 2 2 V at 40 C 104...

Page 316: ...1 and 2 of room temper ature sensor connector at each temperature OK Resistance at 25 C 77 F 1 65 1 75 k at 50 C 122 F 0 55 0 65 k HINT As the temperature increases the resistance decreases NG Replac...

Page 317: ...12 Ambient Temperature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the ambient temperature and sends the appropriate signals to the A C control assembly DTC No Detection Item Trouble Area 1...

Page 318: ...till connected CHECK a Turn ignition switch to ON b Measure voltage between terminals TAM and SG of A C control assembly connector at each temperature OK Voltage at 25 C 77 F 1 35 1 75 V at 40 C 104 F...

Page 319: ...erature OK Resistance at 25 C 77 F 1 6 1 8 k at 50 C 122 F 0 5 0 7 k HINT As the temperature increases the resistance decreases NOTICE When installing the ambient temperature sensor be sure to connect...

Page 320: ...IRCUIT DESCRIPTION This sensor detects the temperature inside the cooling unit and sends the appropriate signals to the A C control assembly DTC No Detection Item Trouble Area 13 Open or short in fron...

Page 321: ...ltage at 0 C 32 F 2 0 2 4 V at 15 C 59 F 1 4 1 8 V HINT As the temperature increases the voltage decreases NG Go to step 2 OK Proceed to next circuit inspection shown on problem symptoms table See pag...

Page 322: ...STEM 862 Author Date 2001 SIENNA RM787U 3 Check harness and connector between A C control assembly and front evapora tor temperature sensor See page IN 31 NG Repair or replace harness or connector OK...

Page 323: ...engine coolant temperature and sends the appropriate signals to the A C amplifier DTC No Detection Item Trouble Area 14 Open or short in engine coolant temperature sensor circuit Engine coolant temper...

Page 324: ...control assembly REFERENCE INSPECTION USING OSCILLOSCOPE PREPARATION a Remove the A C control assembly with connectors still connected b Connect the oscilloscope to terminals TW and GND of A C contro...

Page 325: ...IONING SYSTEM DI 71 1 865 Author Date 2001 SIENNA RM787U 3 Check harness and connector between A C control assembly and ECM See page IN 31 NG Repair or replace harness or connector OK Check and replac...

Page 326: ...ature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the temperature inside the cabin and sends the appropriate signals to the rear A C con trol assembly DTC No Detection Item Trouble Area 19...

Page 327: ...8 2 2 V at 40 C 104 F 1 2 1 6 V HINT As the temperature increases the voltage decreases NG Go to step 3 OK Proceed to next circuit inspection shown on problem symptoms table See page DI 697 Howev er i...

Page 328: ...SYSTEM 868 Author Date 2001 SIENNA RM787U 3 Check harness and connector between A C control assembly and rear room tem perature sensor See page IN 31 NG Repair or replace harness or connector OK Chec...

Page 329: ...lar Sensor Circuit CIRCUIT DESCRIPTION A photo diode in the solar sensor detects solar radiation and sends signals to the A C control assembly DTC No Detection Item Trouble Area 21 Open or short in so...

Page 330: ...etween terminals S5 and TS of A C control assembly connector when the solar sensor is sub jected to an electric light and when the sensor is covered by a cloth OK Condition Voltage Sensor subjected to...

Page 331: ...ega tive lead to terminal 2 of the solar sensor OK Resistance no continuity PREPARATION a Remove the cloth from the solar sensor and subject the sensor to electric light b Measure resistance OK Resist...

Page 332: ...ivided by the engine speed is smaller than a predetermined value the A C control assembly turns the compressor OFF And the indicator flashes at about 1 second intervals DTC No Detection Item Trouble A...

Page 333: ...e started and blower switch and A C switch ON NG Adjust drive belt tension or repair compressor OK 2 Check compressor lock sensor PREPARATION Disconnect compressor connector CHECK Measure resistance b...

Page 334: ...ness and connector between A C control assembly and compressor lock sensor See page IN 21 NG Repair or replace harness or connector OK Proceed to next circuit inspection shown on problem symptoms tabl...

Page 335: ...TION The pressure switch sends the appropriate signals to the A C amprifier when the A C refrigerant pressure drops too low or rises too high When the A C control assembly receives these signals it ou...

Page 336: ...of A C control assembly PREPARATION Install the manifold gauge set CHECK a Turn ignition switch ON b Check voltage between terminal PSW of A C control as sembly connector and body ground when refrige...

Page 337: ...itch PREPARATION Disconnect pressure switch connector CHECK a Turn ignition switch ON b Check continuity between terminals 1 and 4 of pressure switch when refrigerant pressure is changed OK The contin...

Page 338: ...erature Sensor Circuit CIRCUIT DESCRIPTION This sensor detects the rear heater intake air temperature and sends the appropriate signals to the A C con trol assembly DTC No Detection Item Trouble Area...

Page 339: ...nectors still connected CHECK a Turn ignition switch to ON b Measure voltage between terminals TINH and SG of A C cotrol assembly connector at each temperature OK Voltage at 25 C 77 F 1 8 2 2 V at 40...

Page 340: ...d 2 of rear heater intake air temperature sensor connector at each temperature OK Resistance at 25 C 77 F 1 65 1 75 k at 50 C 122 F 0 55 0 65 k HINT As the temperature increases the resistance decreas...

Page 341: ...propriate signals to the A C control assembly The position sensor is built into the air mix damper control ser vomotor assembly DTC No Detection Item Trouble Area 31 Short to ground or power source ci...

Page 342: ...the set temperature to activate the front air mix damper control servomotor and measure the voltage be tween terminals TPD and SG of A C control assembly connector each time when the set temperature i...

Page 343: ...rvomotor follow ing the procedure measure resistance between terminals 1 and 3 of front air mix damper control servomotor assembly con nector OK Position Resistance Max cool 3 6 6 8 k Max warm 0 5 1 1...

Page 344: ...e appropriate signals to the A C control assembly The position sensor is built into the air inlet damper control ser vomotor assembly DTC No Detection Item Trouble Area 32 Short to ground or power sou...

Page 345: ...e air inlet between fresh and re circulation air and measure voltage between terminals TPI and SG of A C control assembly when the air inlet damper control servomotor operates OK FRS REC Switch Voltag...

Page 346: ...he procedure on page DI 739 measure resistance between terminals 1 and 5 of air inlet damper control servomotor assem bly connector OK Resistance Damper Position Resistance REC side 3 1 5 8 k FRS side...

Page 347: ...mper and sends the appropriate signals to the rear A C control assembly The position sensor is built into the rear air mix damper control servomotor assembly DTC No Detection Item Trouble Area 37 Shor...

Page 348: ...e set temperature to activate the rear air mix damper control servomotor and measure the voltage be tween terminals TPr and SG of A C control assembly con nector each time when the set temperature is...

Page 349: ...control servomotor follow ing the procedure measure resistance between terminals 3 and 4 of rear air mix damper control servomotor assembly con nector OK Position Resistance Max COOL 3 6 6 8 k Max WAR...

Page 350: ...41 Front Air Mix Damper Control Servomotor Circuit CIRCUIT DESCRIPTION The front air mix damper control servomotor is controlled by the A C control assembly and moves the air mix damper to the desired...

Page 351: ...page DI 689 c Press the DEF switch and change it to step operation CHECK Press the DEF switch and check the operation of the air mix damper and the condition of the blower OK Display Code Air Mix Damp...

Page 352: ...nal 4 and negative lead to terminal 5 CHECK Connect positive lead to terminal 5 and negative lead to terminal 4 OK The lever turns smoothly to COOL side OK The lever turns smoothly to WARM side NG Rep...

Page 353: ...rvomotor Circuit CIRCUIT DESCRIPTION The air inlet damper control servomotor is controlled by the A C control assembly and moves the air inlet damper to the desired position DTC No Detection item Trou...

Page 354: ...and check the air inlet damper operation b Set to the actuator check mode See page DI 689 c Press the DEF switch and change it to step operation CHECK Press the DEF switch and check the operation air...

Page 355: ...inal 5 and negative lead to terminal 4 OK The lever moves smoothly to RECIRCULATION position CHECK Connect positive lead to terminal 4 and negative lead to terminal 5 OK The lever moves smoothly to FR...

Page 356: ...RM787U DTC 47 Rear Air Mix Damper Control Servomotor Circuit CIRCUIT DESCRIPTION The rear air mix damper control servomotor is controlled by the A C control assembly and moves the air mix damper to t...

Page 357: ...lead to terminal 1 and negative lead to terminal 2 OK The lever turns smoothly to WARM side CHECK Connect positive lead to terminal 2 and negative lead to terminal 1 OK The lever turns smoothly to CO...

Page 358: ...4 4 4 4 4 3 2 1 5 Front Heater Relay Passenger Side R B No 4 A24 2 To Blower Motor J2 J C A A W B W B IJ A C Control Assembly HR B B IK7 1 1 6 4 W W L R L DI 756 DIAGNOSTICS AIR CONDITIONING SYSTEM 91...

Page 359: ...nd body ground PREPARATION Remove A C control assembly with connectors still connected See page AC 1 16 CHECK Measure voltage between terminal HR of A C control assembly and body ground when ignition...

Page 360: ...Continuity 3 5 62 5 90 9 PREPARATION Apply battery positive voltage between terminals 3 and 5 CHECK Check continuity between each pair of terminal shown below OK Tester connection Specified condition...

Page 361: ...DESCRIPTION This A C control assembly monitors the engine speed through signals sent from the igniter The A C control assembly uses these signals and compressor speed signals to detect the compressor...

Page 362: ...s and connector between A C control assembly and ECM See page IN 31 NG Repair or replace harness or connector OK 3 Check harness and connector between A C control assembly and combination meter See pa...

Page 363: ...B L W 2L 2 2D 2 Engine Room J B No 2 3C 20 J B No 3 3C 9 A C cotrol assembly A25 IG 10 R L A25 GND 1 BR ED DIAGNOSTICS AIR CONDITIONING SYSTEM DI 749 903 Author Date 2001 SIENNA RM787U IG Power Sourc...

Page 364: ...sts NG Check for shot in all the harness and compo nents connected to the HEATER fuse See page IN 31 OK 2 Check voltage between terminals IG and GND of A C control assembly connec tor PREPARATION a Re...

Page 365: ...ntinuity between terminal GND of A C control assembly and body ground CHECK Measure resistance between terminal GND of A C control as sembly and body ground OK Resistance Below 1 NG Repair or replace...

Page 366: ...5 Y B G O P L BR R R W IE2 IE2 IE2 IE2 IC1 IE2 IC1 IC1 5 1 2 3 4 4 1 1 J7 J C E E R R B O Y R Y B G O P L BR R R W A24 A24 A24 A24 A23 A25 A23 A24 RG TSET RBAT SG S5 18 4 5 6 7 12 1 DI 784 DIAGNOSTIC...

Page 367: ...INSPECTION PROCEDURE 1 Check voltage between terminals RBAT RLO RME RHI and RG of A C control assembly PREPARATION Remove A C control assembly with connectors with still con nected CHECK a Turn ignit...

Page 368: ...of rear A C control panel when switch is operated as shown in the chart OK Switch position Tester connection Specified condition OFF No continuity AUTO 1 8 Continuity LO 1 4 Continuity ME 1 3 Continui...

Page 369: ...ater Blower Switch W B A24 8 RRAT A24 A24 9 18 RROM RG OR G V R R AUTO H8 H8 H8 8 5 1 HI E DIAGNOSTICS AIR CONDITIONING SYSTEM DI 781 935 Author Date 2001 SIENNA RM787U Rear Blower Switch Front Side C...

Page 370: ...or Date 2001 SIENNA RM787U INSPECTION PROCEDURE 1 Check voltage between terminals RRAT RRON of A C amplifier and body ground PREPARATION Remove A C control assembly with connectors still connected CHE...

Page 371: ...rear A C main switch when switch operation as shown in the chart OK Switch position Tester connection Specified condition OFF No continuity REAR 1 6 8 Continuity AUTO 5 6 8 Continuity NG Replace rear...

Page 372: ...om Compartment Right A25 17 W B A C Control Assembly HRC L W B L W L IK8 5 B L To Blower Motor IK8 4 R L R L R L HEATER AM1 1K 1 7 7 2 1 R B No 7 AM1 IG1 W DI 762 DIAGNOSTICS AIR CONDITIONING SYSTEM 9...

Page 373: ...nd body ground PREPARATION Remove A C control assembly with connectors still connected See page AC 1 16 CHECK Measure voltage between terminal HRC of A C control assem bly and body ground when ignitio...

Page 374: ...2 5 90 9 PREPARATION Apply battery positive voltage between terminals 3 and 5 CHECK Check continuity between each pair of terminal shown below OK Tester connection Specified condition 1 2 Continuity 2...

Page 375: ...5 5 5 4 3 2 1 5 Rear Heater Relay Driver Side R B No 5 A24 16 To Blower Motor J2 J C A A W B W B IJ A C Control Assembly HRH L B ED1 2 L B 5 1 4 W W L DIAGNOSTICS AIR CONDITIONING SYSTEM DI 759 913 A...

Page 376: ...nd body ground PREPARATION Remove A C control assembly with connectors still connected See page AC 1 16 CHECK Measure voltage between terminal HRH of A C control assem bly and body ground when ignitio...

Page 377: ...ontinuity 3 5 62 5 90 9 PREPARATION Apply battery positive voltage between terminals 3 and 5 CHECK Check continuity between each pair of terminal shown below OK Tester connection Specified condition 1...

Page 378: ...CIRCUIT DESCRIPTION This A C control assembly monitors the vehicle speed through signals sent from the speed sensor The A C control assembly uses these signals to revice the ambient temperature sensor...

Page 379: ...SYSTEM DI 753 907 Author Date 2001 SIENNA RM787U 2 Check harness and connector between A C control assembly and combination meter See page IN 31 NG Repair or replace harness or connector OK Check and...

Page 380: ...ge Always Hi Always Med Always Lo Air Flow Control is Faulty Cabin temperature does not go down Response is slow Cannot change between FRS and REC Always Fresh or always Recirculating Will not enter t...

Page 381: ...or circuit Open Solar sensor Harness or connector between solar sensor and A C control 21 3 DI 715 Solar sensor circuit Short Harness or connector between solar sensor and A C control assembly A C amp...

Page 382: ...ar Air mix damper control servomotor circuit Air mix damper control servomotor Air mix damper position sensor Harness and connector between A C control assembly and air mix position sensor Harness and...

Page 383: ...ir Confirmation Test End Items inside are titles of pages 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 P D...

Page 384: ...AUTO Indicates a switch operation DEF DEF DEF DEF DIAGNOSTICS AIR CONDITIONING SYSTEM DI 689 843 Author Date 2001 SIENNA RM787U PRE CHECK 1 WARNING FOR A C COMPRESSOR LOCK If compressor lock occurs d...

Page 385: ...tomatically Press the OFF switch when desiring to cancel the check mode 4 DTC CHECK SENSOR CHECK a Perform an indicator check After the indicator check is completed the system enters the DTC check mod...

Page 386: ...After entering the sensor check mode press the R F switch b Since each damper motor and relay automatically oper ates at 1 second intervals beginning in order from 20 in the temperature display check...

Page 387: ...p sensor circuit 10 A C control assembly AC 3 AC 17 AC 3 DI 776 DI 721 DI 727 DI 736 DI 712 DI 703 IN 31 Temperature Control No warm air comes out 1 Front air mix damper position sensor circuit 2 Fron...

Page 388: ...uit 5 A C control assembly DI 712 DI 703 DI 727 DI 736 IN 31 No air inlet control 1 Front air inlet damper position sensor circuit 2 Front air inlet damper control servomotor circuit 3 A C control ass...

Page 389: ...ection with manifold gauge set 4 Expansion valve 5 Evaporator 6 Compressor circuit 7 Rear air mix damper position sensor circuit 8 Rear air mix damper control servomotor circuit 9 Rear room temp senso...

Page 390: ...ntake air temp 40 C 104 F 1 2 1 6 V TSET SG G O BR R IG ON Set rear A C temp Max COOL 5 0 V TSET SG A23 12 A24 18 G O BR R IG ON Set rear A C temp Max WARM Below 1 0V FACE GND R B BR IG ON Air flow se...

Page 391: ...ar blower blower motor Not operate 10 14 V BLWH GND Y G BR IG ON Set rear A C temp Max COOL Rear blower blower motor Operate Below 1 0 V BLWH GND A24 15 A25 1 Y G BR IG ON Set rear A C temp Max COOL R...

Page 392: ...t A C temp Max COOL Rear A C blower switch ON Below 1 0 V BLWC GND A25 18 A25 1 P B BR IG ON Set front A C temp Max COOL Rear A C blower switch ON 10 14 V IG ON Set rear A C temp Max WARM Rear blower...

Page 393: ...T 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...

Page 394: ...of ECM and body ground OK Voltage 10 14 V OK Proceed to next circuit inspection shown in matrix chart See page DI 171 NG 2 Check voltage between terminal OD of cruise control ECU harness side connec...

Page 395: ...TRANSAXLE DI 203 357 Author Date 2001 SIENNA RM787U 3 Check harness and connector between cruise control ECU and ECM See page IN 31 NG Repair or replace the harness or connector OK Check and replace...

Page 396: ...C D D GR AM1 1 2 1 2 1 w o VSC 2 w VSC DI 204 DIAGNOSTICS AUTOMATIC TRANSAXLE 358 Author Date 2001 SIENNA RM787U O D Main Switch O D OFF Indictor Light Circuit CIRCUIT DESCRIPTION The O D main switch...

Page 397: ...ight lights up b O D OFF indicator light goes off OK Proceed to next inspection shown on problem symptoms tables See page DI 171 NG 2 Check and replace the combination meter See page BE 48 NG Replace...

Page 398: ...Press continuously O D main switch Below 1 0 V Release O D main switch 10 14 V OK Check and replace the ECM See page IN 21 NG 5 Check voltage between terminal ODLP of ECM and body ground PREPARATION...

Page 399: ...t to the combination meter After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit in side the combination meter it is then transmitted to the ECM The E...

Page 400: ...h etc at the time of the malfunction 1 Check operation of speedometer CHECK Drive the vehicle and check if the operation of the speedometer in the combination meter is normal HINT The vehicle speed se...

Page 401: ...tween terminal SPD of the ECM connector and body ground OK Voltage 9 14 V NG Check for open in harness and connector be tween junction connector J15 and ECM See page IN 31 OK 4 Check for open in harne...

Page 402: ...ture sensor converts fluid temp into a resistance valve which is input into the ECM DTC No DTC Detecting Condition Trouble Area P0710 Either a or b is detected for 0 5 sec or more 2 trip detection log...

Page 403: ...page IN 31 NG Repair or replace the harness or connector OK 2 Check ATF temperature sensor PREPARATION a Remove the oil pan b Remove the solenoid wiring CHECK Measure resistance between terminals 2 an...

Page 404: ...he ECM does not match the actual gear 2 trip detection logic Shift solenoid valve No 1 and or No 2 is stuck open or closed Valve body is blocked up or stuck Automatic transaxle clutch brake or gear et...

Page 405: ...DI 180 DIAGNOSTICS AUTOMATIC TRANSAXLE 334 Author Date 2001 SIENNA RM787U 2 Check the valve body See page DI 171 NG Repair or replace valve body OK Repair the transaxle See page AX 25...

Page 406: ...nction If either of the shift solenoid valve circuits develops an open or short the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below The ECM also t...

Page 407: ...DI 182 DIAGNOSTICS AUTOMATIC TRANSAXLE 336 Author Date 2001 SIENNA RM787U WIRING DIAGRAM INSPECTION PROCEDURE 1 Measure resistance between terminal S1 or S2 of ECM and body ground PREPARATION Disconn...

Page 408: ...d connector between ECM and automatic transaxle solenoid connector PREPARATION Disconnect the solenoid connector from the automatic trans axle CHECK Measure resistance of the harness and connector bet...

Page 409: ...the shift solenoid valve No 1 or No 2 CHECK a Measure resistance between solenoid connector and body ground b Connect the positive lead to terminal of solenoid con nector negative lead to solenoid bod...

Page 410: ...Detecting Condition Trouble Area P0770 Lock up does not occur when driving in the lock up range normal driving at 80 km h 50 mph or lock up remains ON in the lock up OFF range 2 trip detection logic W...

Page 411: ...340 Author Date 2001 SIENNA RM787U 2 Check valve body See page DI 171 NG Repair or replace the valve body OK 3 Check the torque converter clutch See page AX 31 NG Repair the torque converter clutch O...

Page 412: ...ic pressure acting on the lock up relay valve which then controls operation of the lock up clutch Fail safe function If the ECM detects a malfunction it turns the shift solenoid valve SL OFF DTC No DT...

Page 413: ...rminal SL of ECM and body ground OK Resistance 11 15 at 20 C 68 F OK Check and replace the ECM See page IN 31 NG 2 Measure resistance of harness and connector between ECM and automatic transaxle solen...

Page 414: ...solenoid valve SL CHECK a Measure resistance between terminal SL of shift solenoid valve and solenoid body b Connect positive lead to terminal of solenoid connec tor negative lead to solenoid body OK...

Page 415: ...en brakes are suddenly applied When the brake pedal is operated this switch sends a signal to ECM Then the ECM cancels operation of the lock up clutch while braking is in progress DTC No DTC Detecting...

Page 416: ...and appropriately controls the engine torque and hydrau lic pressure in response to various conditions thus performing smooth gear shifting DTC No DTC Detecting Condition Trouble Area P1705 The ECM d...

Page 417: ...IN 31 NG 2 Check direct clutch speed sensor PREPARATION Remove the Direct clutch speed sensor from transaxle CHECK a Measure resistance between terminals 1 and 2 of speed sensor b Check voltage betwee...

Page 418: ...cumulator control valve when gears are shifted and performs smooth gear shifting The ECM determines optimum operating pressure according to the signals from the throttle position sensor vehicle speed...

Page 419: ...D07911 G W B Y SLN E12 E1 E12 ECM 20 SLN 19 Shift Solenoid Valve SLN 8 3 Transaxle DI 194 DIAGNOSTICS AUTOMATIC TRANSAXLE 348 Author Date 2001 SIENNA RM787U WIRING DIAGRAM...

Page 420: ...battery positive voltage is sup plied Valve moves in direction shown in il lustration on the left When battery positive voltage is cut off Valve moves in direction shown in il lustration on the right...

Page 421: ...Author Date 2001 SIENNA RM787U 2 Check harness and connector between battery and shift solenoid valve SLN shift solenoid valve SLN and ECM See page IN 31 NG Repair or replace the harness or connector...

Page 422: ...eutral position switch When the signal is not sent to the ECM from the park neutral position switch the ECM judges that the shift lever is in D position DTC No DTC Detection Condition Trouble Area P17...

Page 423: ...A J7 L C 1J 1K 3 4 Driver Side J B No 1 STARTER R 4 3 8 2 7 ST2 AM2 IG1 AM1 ACC B Y L 1J 1K 1K 1J 1 6 6 1 Driver Side J B No 1 GAUGE CIG Driver Side J B No 1 W L W R W W 1K 1K 1B 1B 1 2 5 5 AM1 2D 2B...

Page 424: ...o 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 2 and L positions and read the PNP REVERSE 2ND and LOW signals on the TOYOTA hand...

Page 425: ...CK Check continuity between each terminal shown below when the shift lever is moved to each position Shift Position Terminal No to continuity P 2 7 5 6 R 2 8 N 2 9 5 6 D 2 10 2 2 3 L 2 4 OK There is c...

Page 426: ...mile Shift point too high or too low No up shift 1st 2nd Lock up malfunction Harsh engagement No down shift 3rd O D N D 2nd 1st 2nd 3rd 3rd 2nd O D 3rd Slip or shudder No kick down Malfunction code Co...

Page 427: ...ft solenoid valve No 2 is stuck open or closed Valve body is blocked up or stuck Automatic transaxle clutch brake or gear etc P0758 DI 181 Shift Solenoid B Electrical Mal function Shift Solenoid Valve...

Page 428: ...ated in the bottom portion See the indicated pages for detailed explanations Preliminary Check are titles of pages in the manual with Items inside Mechanical System Tests DTC Chart Chapter 1 Electroni...

Page 429: ...ain Switch O D OFF Indicator Light DLC3 Stop Light Switch Shift Solenoid Valve Park Neutral Position Switch Shift Solenoid Valve SLN Direct Clutch Speed Sensor DIAGNOSTICS AUTOMATIC TRANSAXLE DI 169 3...

Page 430: ...ive system components which affect 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 p...

Page 431: ...light up 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 Terminal No Connection Voltag...

Page 432: ...nd freeze frame data and note them down 1 Prepare an OBD II scan tool complying with SAE J1978 or TOYOTA hand held tester 2 Connect the OBD II scan tool or TOYOTA hand held tester to DLC3 at the lower...

Page 433: ...hand held tester 4 Connect the TOYOTA hand held tester to DLC3 at the lower of the instrument panel 5 Turn the ignition switch ON and switch the TOYOTA hand held tester ON 6 Switch the TOYOTA hand hel...

Page 434: ...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 torqu...

Page 435: ...n 5 and after shifting into the P position release the parking brake Then check to see that the parking lock pawl holds the vehicle in place 5 BASIC INSPECTION a Check the fluid level HINT Drive the v...

Page 436: ...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 80 C 158 176 F and add as necessary N...

Page 437: ...ing the shift lever lightly toward the R position side tighten the shift lever nut Torque 13 N m 130 kgf cm 9 ft lbf 6 Start the engine and make sure that the vehicle moves forward when shifting the l...

Page 438: ...ow in D position Engine output may be insufficient Stator one way clutch is operating properly HINT If more than 600 rpm below the specified value the torque converter clutch could be faulty b Stall s...

Page 439: ...tester to DLC3 5 Start the engine and check idling speed 6 Keep your left foot pressing firmly on the brake pedal and shift into D position 7 Measure the line pressure when the engine is idling 8 Dep...

Page 440: ...t the shift and gear positions correspond with the table below While driving shift through the L 2 and D positions Check that the gear change corresponds to the shift posi tion Shift Position Gear Pos...

Page 441: ...re no abnormalities in any of the other circuits then check and replace the ECM Chapter 1 Electronic circuit matrix chart Symptom Suspect Area See page No up shift A particular gear from 1st to 3rd ge...

Page 442: ...ck up off 1 Lock up relay valve 2 Off vehicle repair matrix chart Harsh engagement N D 1 C1 accumulator 2 Off vehicle repair matrix chart Harsh engagement N R 1 C2 accumulator 2 No 1 accumulator contr...

Page 443: ...O D one way clutch F0 3 No 2 one way clutch F2 Harsh engagement N R 1 Direct clutch C2 2 1st reverse brake B3 Harsh engagement Lock up Torque converter clutch Slip or shudder Forward position After w...

Page 444: ...2 20 SLN E12 19 B Y G W IG ON 10 14 OD1 E9 24 E1 E11 17 B L BR IG ON 5 6 L E10 13 E1 E11 17 Y BR IG ON and Shift lever L position 10 14 L E10 13 E1 E11 17 Y BR IG ON and Shift lever other than L posit...

Page 445: ...iver Side J B NO 1 7 BG2 2 R W 4 1S Body ECU Integration Relay BKL 8 J21 J C B B R W R W W B BG2 BK W B DIAGNOSTICS BODY CONTROL SYSTEM DI 667 821 Author Date 2001 SIENNA RM787U Driver buckle switch c...

Page 446: ...driver buckle switch See page BE 43 NG Replace the driver buckle switch OK 2 Check wireharness and connector between driver buckle switch and body ground See page IN 31 NG Repair or replace wireharne...

Page 447: ...n Relay Y Y LSWP LSWD I13 16 J4 J C 4 BR R IG2 BR R BR R IJ2 IA1 IA3 4 4 6 3 2 I I W B 4 1 Front LH Door Unlock Detec tion Switch D21 4 1 W B D D C C BR R W B DIAGNOSTICS BODY CONTROL SYSTEM DI 655 80...

Page 448: ...nlock detection switch See page BE 73 NG Replace the door lock assembly OK 2 Check wireharness and connector between door unlock detection switch and body ground See page IN 31 NG Repair or replace wi...

Page 449: ...3 IA1 IA3 IJ1 I F LG LG LG W B W B G L R L R L R L R LG Lock Unlock Door Lock Contorol Switch Front LH P11 9 8 D B B 6 5 3 L1 UL1 W B 18 10 B D Body ECU Integration Relay 7 6 4 J C J11 DIAGNOSTICS BOD...

Page 450: ...ock contorol switch See page BE 73 NG Replace the door lock contorol switch OK 2 Check wireharness and connector between door lock contorol switch and body ground See page IN 31 NG Repair or replace w...

Page 451: ...nnector 1 G W 6 G W G W G W W B A22 Junction Connector Door Courtesy SW Front LH Slide Door Courtesy SW LH II2 R G R G 2 1V R G 3D 17 3D 15 3D 17 R Y 2 R Y R Y 2 R Y 1 A R Y 1 R Y 1 8 I16 1 w Door Loc...

Page 452: ...st be operated normally OK Proceed to next circuit inspection shown on problem symptom table See page DI 636 NG 2 Check courtesy switch See page BE 31 NG Replace the courtesy switch OK 3 Check wirehar...

Page 453: ...R L B L R 2 1 3 Door Lock Motor And Unlock Detec tion Switch Front RH D22 L B II5 17 II5 3 L B L R L R IC1 3 IC1 8 BB2 4 1 BD2 5 4 BB2 BD2 S12 S12 S12 S13 S13 S13 S13 S14 S14 S14 S14 S15 S15 2 3 1 4 2...

Page 454: ...E 1 Check door lock motor See page BE 73 NG Replace the door lock motor OK 2 Check wireharness and connector between door lock motor and body ECU See page IN 31 NG Repair or replace wireharness or con...

Page 455: ...A 10 12 SHOT PIN DOME FL MAIN R G 2 PCTY 3 4 12 2J 2B 1V 10 3 1W R A A J18 J C W B L 1 2 R W 1 17 I13 Engine Room J B No 2 Drive side J B No 1 1 w Door Lock Control 2 w o Door Lock Control DIAGNOSTICS...

Page 456: ...or warnig light CHECK Check continuity of DOOR and open door warning light OK Continuity NG Replace the failure fuse OK 2 Check wireharness and connector between Integration Relay and Battery OK Proce...

Page 457: ...de J B NO 1 GR G GR 2 GR GR 1 GR 1 J18 J C A A D C9 9 9 1T 9 I12 IG1 AM1 2 4 2 1 1K 1D 2 1 1B 1K 2 1 W L B Y GAUGE 2 2D 2 2L Engine Room J B NO 2 4 1 ALT INP F8 FL Block FL MAIN Battery B L W W 1 w VS...

Page 458: ...2 Check Wireharness and connector between Integration Relay and Battery PREPARATION a Turn ignition switch ON b Disconnect the instrument panel integration ECU CHECK Measure voltage between terminals...

Page 459: ...Light Relay Main B L EB1 DIAGNOSTICS BODY CONTROL SYSTEM DI 647 801 Author Date 2001 SIENNA RM787U Headlight relay circuit CIRCUIT DESCRIPTION Head light relay will be ON by operating the headlight s...

Page 460: ...light relay See page BE 17 NG Replace the headlight relay OK 2 Check wireharness and connector between headlight relay and Body ECU bat tery and headlight relay See page IN 31 NG Repair or replace wir...

Page 461: ...G B IG2 H6 H5 High Low B L G B G B G B 12 T4 HORN B Theft Deterrent ECU DIAGNOSTICS BODY CONTROL SYSTEM DI 677 831 Author Date 2001 SIENNA RM787U Horn circuit CIRCUIT DESCRIPTION When the theft deter...

Page 462: ...SPECTION PROCEDURE 1 Check horn NG Replace the horn OK 2 Check wireharness and connector between horn relay and body ECU battery and horn relay NG Repair or replace wireharness or connector OK Proceed...

Page 463: ...M DI 659 813 Author Date 2001 SIENNA RM787U Illumination circuit CIRCUIT DESCRIPTION Receiving the courtesy signal from either of the door ECU the Body ECU will make the interior light ignition light...

Page 464: ...Vanity Light LH V5 2 1 1 w Door Lock contorol 2 w o Door Lock contorol 3 w Vanity Light 4 w o Vanity Light 5 w Moon Roof 6 w o Moon Roof 7 Fade out Type 3 A R 2 R A 2 1M B R B Engine Room J B NO 2 R...

Page 465: ...1 L2 Luggage Compartment Light G W G W BB1 BD1 9 5 G W B6 Back Door Courtesy SW 2 1 W B A J22 J C BN G W 6 IC2 1 2 D10 DIODE G B 2 G W 1 F F J18 J C G W 1 1 w Door Lock Control 2 w o Door Lock Contro...

Page 466: ...rior light system See page BE 31 NG Replace the failure light OK 2 Check wireharness and connector between each illumination light and Body ECU battery and each illumination light See page IN 31 NG Re...

Page 467: ...LH D18 I I I F IC2 BB2 BD2 BD2 IJ1 IJ1 IA3 IA1 IG2 IG2 IA3 5 7 J5 J C F 5 6 2 1 20 8 6 A 4 6 1 21 6 7 F C C C J5 J C J11 J C E E Door Keylock And Unlock Switch Front RH D19 B J11 J C Lock Lock Unlock...

Page 468: ...and unlock switch See page BE 73 NG Replace the key lock and unlock switch OK 2 Check wireharness and connector between key lock and unlock switch and body ground See page IN 31 NG Repair or replace...

Page 469: ...SYSTEM DI 673 827 Author Date 2001 SIENNA RM787U Key unlock warning switch circuit CIRCUIT DESCRIPTION The key unlock warning switch goes on when the ignition key is inserted in the key cylinder and...

Page 470: ...nlock warning switch See page BE 15 NG Replace the key unlock warning switch OK 2 Check wireharness and connector between key unlock warning switch and Body ECU See page IN 31 NG Repair or replace wir...

Page 471: ...ECU Integration Relay CLTS CLTB 3 4 1 G B R G B LG R IG2 ID1 9 9 18 I13 I13 22 23 Automatic Light Contorol Sensor DIAGNOSTICS BODY CONTROL SYSTEM DI 675 829 Author Date 2001 SIENNA RM787U Light conto...

Page 472: ...IENNA RM787U INSPECTION PROCEDURE 1 Check wirehaness and connector between Automatic light contorol sensor as sembly and Body ECU NG Repair or replace wireharness or connector OK Proceed to next circu...

Page 473: ...FF TAIL HEAD AUTO LOW HIGH FLASH J C W B ED W B L i g h t Co n t r o l Switch Dim m er Switch 16 I13 I13 7 4 1 2 2 1 12 14 13 2 w o Door Lock Control 1 w Door Lock Control N T A EL DIAGNOSTICS BODY CO...

Page 474: ...dlight control switch See page BE 17 NG Replace the headlight control switch OK 2 Check wireharness and connector between headlight control switch and Body ECU See page IN 31 NG Repair or replace wire...

Page 475: ...k Control B B P B 2 1 2 1 D26 DIODE Buckle SW P 1 3 I13 1 2 DIAGNOSTICS BODY CONTROL SYSTEM DI 671 825 Author Date 2001 SIENNA RM787U Passenger buckle switch and seat belt warning occupant detec tion...

Page 476: ...sensor See page BE 43 NG Replace the seat belt warning occupant Detec tion sensor OK 3 Check wireharness and connector between seat belt warning occupant Detec tion sensor and body ECU passenger buckl...

Page 477: ...DI6LK 03 DIAGNOSTICS BODY CONTROL SYSTEM DI 639 793 Author Date 2001 SIENNA RM787U CIRCUIT INSPECTION Power source circuit CIRCUIT DESCRIPTION This circuit provides power to operate the Body ECU...

Page 478: ...AUGE E P W 1 A R 1M IG 2 DOME J B NO 3 2J 12 W B 1 Driver Side J B NO 1 Driver Side J B NO 1 I12 Ignition Switch B 10 POWER 2 1 B R 3D 19 1K 1 Battery A 2 1 L W F8 4 F9 1 Driver Side J B NO 1 SHORT PI...

Page 479: ...eplace the failure fuse OK 2 Check voltage between terminals P W IG B and E of Body ECU connector PREPARATION Turn ignition switch ON CHECK Measure voltage between terminals IG and E OK Voltage 10 14V...

Page 480: ...hor Date 2001 SIENNA RM787U 3 Check wireharness and connector between Body ECU and body ground See page IN 31 NG Repair or replace wireharness or connector OK Check and repair wireharness and connecto...

Page 481: ...CIG WRNP I12 Ignition Switch Driver Side J B NO 1 2 2 1 1 4 4 5 W C8 I16 16 1J 6 1K 6 FL BLOCK ALT INP FL MAIN B L 2D 2L 1K 2 1B 1 W I13 2 W L 2 2 1 w Door Lock Control 2 w o Door Lock Control 2 1 AM...

Page 482: ...eck Wireharness and connector between Integration Relay and Battery PREPARATION a Turn ignition switch ON b Disconnect the instrument panel integration ECU CHECK Measure voltage between terminals LSDS...

Page 483: ...ntegration Relay IE2 Slide Door RH ECU Slide Door LH ECU RKE L B L B II5 15 10 S30 7 S32 7 I16 18 I16 6 DIAGNOSTICS BODY CONTROL SYSTEM DI 683 837 Author Date 2001 SIENNA RM787U Slide door ECU communi...

Page 484: ...A RM787U INSPECTION PROCEDURE 1 Check wireharness and connector between integration Relay and slide door RH ECU and slide door LH ECU NG Repair or replace wireharness or connector OK Proceed to next c...

Page 485: ...ck Control 1 w Door Lock Control W R I13 B B DIAGNOSTICS BODY CONTROL SYSTEM DI 645 799 Author Date 2001 SIENNA RM787U Taillight relay circuit CIRCUIT DESCRIPTION Taillight relay will be ON by operati...

Page 486: ...light relay See page BE 17 NG Replace the taillight relay OK 2 Check wireharness and connector between taillight relay and Body ECU battery and taillight relay See page IN 31 NG Repair or replace wire...

Page 487: ...CU Integration Relay 1 T3 Theft Deterrent ECU IG2 PANI I16 PANI 10 18 V V DIAGNOSTICS BODY CONTROL SYSTEM DI 685 839 Author Date 2001 SIENNA RM787U Theft deterrent ECU communication circuit WIRING DIA...

Page 488: ...2001 SIENNA RM787U INSPECTION PROCEDURE 1 Check wireharness and connector between theft deterrent ECU and integration Relay NG Repair or replace wireharness or connector OK Proceed to next circuit ins...

Page 489: ...Keyless Buzzer K3 J7 J C J C A A J2 W B B B J3 ED W B G O W B I16 4 1 2 BZR DIAGNOSTICS BODY CONTROL SYSTEM DI 681 835 Author Date 2001 SIENNA RM787U Wireless door lock buzzer circuit WIRING DIAGRAM D...

Page 490: ...r See page BE 81 NG Replace the wireless door lock buzzer OK 2 Check wireharness and connector between wireless door lock buzzer and Body ECU Body ECU and wireless door lock buzzer See page IN 31 NG R...

Page 491: ...J C A R J3 A 2J SHORT PIN 15 I16 G R G Y W B W5 R I16 LSDS IC3 10 W B BM BK DIAGNOSTICS BODY CONTROL SYSTEM DI 679 833 Author Date 2001 SIENNA RM787U Wireless door lock tuner circuit CIRCUIT DESCRIPT...

Page 492: ...nd Body ECU CHECK Check continuity between terminals PRG of wireless door lock tuner and PRG of Body ECU OK Continuity NG Repair or replace wireharness OK 3 Check the wireless door lock tuner CHECK Re...

Page 493: ...mperature Fine Cloudy Rainy Snowy Various Others Hot Warm Cool Cold Approx F C Constant Sometimes times per day month Illuminated Entry System Seat Belt Warning Power Door Lock Control System Wireless...

Page 494: ...h the page number indicated in the bottom portion See the indicated pages for detailed explanations 1 2 3 6 5 P IN 21 P DI 629 P DI 639 DI 681 Symptom occur Step 6 8 Diagnostic steps permitting the us...

Page 495: ...ock Control ECU Ignition Switch Key Unlock Warning Switch Driver Side J B NO 1 Integration Relay Engine Room R B NO 7 Horn Teft Deterrrent Horn Power Slide Door Main Switch Conbination Meter PWD Door...

Page 496: ...witch Rear NO 1 Interior Light Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Door Courtesy Switch Door Courtesy Light Back Door Lock Assembly Door Lock Motor Door Unlock Detection Sw...

Page 497: ...U Integration Relay DI 647 DI 643 DI 632 Lo Beam does not light 1 Headlight bulb 2 Headlight control relay circuit 3 Headlight dimmer switch 4 Body ECU Integration relay DI 647 DI 643 DI 632 Hi Beam d...

Page 498: ...plate 4 Body ECU Integration relay DI 665 DI 667 BE 43 DI 632 Open Door warning light does not light up 1 Warning light circuit 2 Door courtesy switch circuit 3 Illumination circuit 4 Meter circuit pl...

Page 499: ...lock control system 1 Door courtesy switch circuit 2 Body ECU Integration relay DI 657 DI 632 Wireless door lock operates but the buzzer does not sound 1 Wireless door lock buzzer circuit 2 Wireless...

Page 500: ...ened Below 1 V 9 I16 7 W B Driver seat belt buckle switch ON belt Fastened Below 1 V 9 I16 7 WRND GND W B Driver seat belt buckle switch OFF belt Fastened Approx 5 0V 10 Body Ground W B C t t C ti it...

Page 501: ...17 I16 7 R W W B Any door opened Below 1 V I13 17 I16 7 WRN GND R W W B All doors closed 10 14 V I13 21 I16 7 LG W B A t ti li ht t l i ti i it B l 1 V I13 21 I16 7 CSE GND LG W B Automatic light con...

Page 502: ...B l 1 V I16 16 I16 7 Y G W B Ignition switch osition ACC and front assenger seat belt warning light ON Below 1 V I16 16 I16 7 WRNP GND Y G W B Ignition switch position ACC and front passenger seat bel...

Page 503: ...kle switch OFF belt Fastened Approx 5 0V I13 1 10 R Y W B RH slide door opened Below 1 V I13 1 10 SCTY E R Y W B RH slide door closed I13 2 10 Y G W B Ignition switch position ACC and front passenger...

Page 504: ...throttle link are properly installed and that the cable and link are connected correctly b Check that the actuator and bell crank are operating smoothly c Check that the cable is not loose or too tig...

Page 505: ...1 P 18 IH2 11 C15 P B A A BR EC J14 J C DIAGNOSTICS CRUISE CONTROL SYSTEM DI 603 757 Author Date 2001 SIENNA RM787U Diagnosis Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that DT...

Page 506: ...nition switch ON CHECK Measure voltage between terminals Tc and E1 of DLC2 OK Voltage 10 14 V OK Proceed to next circuit inspection shown on problem symptom table See page DI 572 NG 2 Check harness an...

Page 507: ...erated by signals from the ECU Acceleration and deceleration signals are trans mitted by changes in the Duty Ratio See note below Duty Ratio The duty ratio is the ratio of the period of continuity in...

Page 508: ...ctuator connector CHECK Measure resistance between terminals 1 and 2 HINT If control plate position is fully opened or fully closed resistance can not be measured OK Resistance more than 4 2 NG Replac...

Page 509: ...s released When the brake pedal is depressed the stop light switch turns on supplying electrical power to the stop light Power supply to the magnetic clutch is mechanically cut and the magnetic clutch...

Page 510: ...h OFF b Remove the STOP fuse from instrument panel junction block No 1 CHECK Check fuse continuity OK Continuity exists NG Replace STOP fuse OK 2 Check stop light switch PREPARATION Disconnect the sto...

Page 511: ...onnect the actuator connector CHECK Measure resistance between terminals 3 and 4 OK Resistance 34 65 42 35 NG Replace cruise control actuator OK 4 Check for open and short in harness and connectors be...

Page 512: ...ctuator motor Cruise control ECU WIRING DIAGRAM See page DI 573 INSPECTION PROCEDURE 1 Check cruise control actuator arm locking operation PREPARATION a Turn ignition switch OFF b Disconnect the actua...

Page 513: ...1 and 3 of actuator connect the negative lead to terminals 2 and 4 of actuator OK Control arm moves to fully open side CHECK Connect the positive lead from the battery to terminals 2 and 3 of actuato...

Page 514: ...ehicle speed sensor circuit send the vehicle speed signal to the cruise control ECU For each rotation of the shaft the vehicle speed sensor sends a signal through the combination meter to the cruise c...

Page 515: ...h and with vehicle speed below 40 km h 25 mph OK Vehicle speed above 40 km h 25 mph Indicator light blinks Vehicle speed below 40 km h 25 mph Indicator light stays on OK Check and replace cruise contr...

Page 516: ...580 DTC No Detection Item Trouble Area 23 Vehicle speed sensor pulse is abnormal Vehicle speed sensor Cruise control ECU WIRING DIAGRAM See page DI 580 INSPECTION PROCEDURE 1 Check speedometer circui...

Page 517: ...RM787U DTC 32 Control Switch Circuit Cruise Control Switch CIRCUIT DESCRIPTION This circuit carries the SET COAST RESUME ACCEL and CANCEL signals each voltage to the ECU DTC No Detection Item Trouble...

Page 518: ...ble 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 goes off when the cancel switch is turned ON OK Wait...

Page 519: ...l switch connector when control switch is operated Switch position Resistance Neutral No continuity RES ACC 50 80 SET COAST 180 220 CANCEL 400 440 NG Replace control switch OK 4 Check harness and conn...

Page 520: ...cy between the throttle valve position and the actuator position sensor value to enable accurate cruise control at the set speed If the idle switch is malfunctioning problem symptoms also occur in the...

Page 521: ...CHECK Measure voltage between terminal IDL of ECU connector and body ground when the throttle valve is fully closed and fully opened OK Throttle valve position Voltage Fully opened 10 14 V Fully clos...

Page 522: ...erminals 3 and 4 of throttle posi tion sensor connector when the throttle valve is fully closed and fully opened OK Throttle valve position Resistance Fully opened 1 M or higher Fully closed Below 2 3...

Page 523: ...g when down shifting in the electronically controlled transmission occurs a signal to prevent upshift until the end of the up hill slope is sent from the cruise control ECU to the electronically contr...

Page 524: ...ation of OD switch ON OFF NG Check and repair electronically controlled transmission See page DI 204 OK 2 Check voltage between terminal OD of harness side connector of cruise control ECU and body gro...

Page 525: ...switch position Voltage ON 8 14 V OFF Below 0 5 V OK Proceed to next circuit inspection shown on problem symptom table See page DI 572 NG 4 Check harness and connector between terminal ECT of cruise...

Page 526: ...r Side J B No 1 9 1K 1J 1 ECU IG B O C15 9 B GND C15 J B No 3 10 10 3C 3B 16 W B IG W B IG1 AM1 2 1 DI 598 DIAGNOSTICS CRUISE CONTROL SYSTEM 752 Author Date 2001 SIENNA RM787U ECU Power Source Circuit...

Page 527: ...No 1 CHECK Check continuity 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 contro...

Page 528: ...etween terminal GND of cruise control ECU connector and body ground CHECK Measure resistance between terminal GND of ECU connector and body ground OK Resistance Below 1 NG Repair or replace harness or...

Page 529: ...A Driver Side J B No 1 Driver Side J B No 1 1 1K 3 2 1 2 2L Engine Room J B No 2 2 2D I12 4 F8 W L 2 1D GAUGE A J17 J C J18 J C GR 1 GR 1 D D 1 w VSC 2 w o VSC DIAGNOSTICS CRUISE CONTROL SYSTEM DI 601...

Page 530: ...TION Tun ignition switch ON CHECK Measure voltage between terminals PI and GND of cruise con trol ECU connector when main switch is on and off OK Switch position Voltage OFF 10 16 V ON Below 1 2 V OK...

Page 531: ...12 P 3 J C R L 4 4 w o Wireless Door Lock Control 1 w VSC 2 w o VSC 12 26 D CCS ACC 3 Cruise Control ECU 3 1K 6 L B Y 1J 6 1K 1 1D 2 CIG GAUGE DIAGNOSTICS CRUISE CONTROL SYSTEM DI 595 749 Author Date...

Page 532: ...peration CHECK Check that the starter operates normally and that the engine starts NG Proceed to engine troubleshooting See page DI 1 OK 2 Input signal check PREPARATION See input signal check on page...

Page 533: ...rminal D of ECU connector and body ground when shifting into D position and other positions OK Shift Position Voltage D position 10 14 V Other positions Below 1 V OK Proceed to next circuit inspection...

Page 534: ...the cruise control A fail safe function is provided so that the cancel functions normally even if there is a malfunction in the stop light signal circuit The cancel conditions are Battery positive vo...

Page 535: ...Check that stop light comes on when brake pedal is depressed and turns off when brake pedal is released NG Check stop light system See page BE 2 OK 2 Input signal check CHECK a See input signal check...

Page 536: ...Measure voltage between terminal STP of cruise control ECU connector and body ground when the brake pedal is de pressed and released OK Depressed 10 14 V Released Below 1 V OK Proceed to next circuit...

Page 537: ...curred did the driver activate cruise control again Yes No Cancel does not occur With brake ON Except D position shift When control SW turns to CANCEL position Cruise control malfunction Slip to accel...

Page 538: ...se control ECU 14 DI 578 Actuator Mechanical Malfunction Actuator motor actuator lock motor arm Cruise control ECU 21 DI 580 Open in Vehicle Speed Sensor Circuit Combination meter Harness or connector...

Page 539: ...pair Confirmation Test End Items inside are titles of pages 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 P...

Page 540: ...tch Engine Room Junction Block No 2 ECU B Fuse Cruise Control ECU Cruise Control switch Main Switch Control Switch Instrument Panel Junction Block No 1 ECU IG Fuse STOP Fuse Park Neutral Position Swit...

Page 541: ...heck result is not normal proceed to trouble shooting See page BE 2 for the combination meter section b Check the DTC HINT If a malfunction occurs in the No 1 vehicle speed sensors or ac tuator etc du...

Page 542: ...21 are shown in the illustration 2 DTC CLEARANCE ERASE MODE HINT Under the erase mode diag detection does not work a Drive at about 15 km h or below b Using SST connect terminals Tc and E1 of DLC1 SST...

Page 543: ...the control switch upward to RES ACC 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 Push the main switch ON 2 Dr...

Page 544: ...the main switch OFF Pull the cruise control switch to CANCEL e Inspect the RESUME switch 1 Push the main switch ON 2 Drive at a desired speed 40 km h 25 mph or high er 3 When operating one of the fol...

Page 545: ...FF 1sec 0 25 sec 0 25 sec Turn clutch switch OFF Depress clutch pedal Clutch switch circuit is normal DIAGNOSTICS CRUISE CONTROL SYSTEM DI 567 721 Author Date 2001 SIENNA RM787U 4 INPUT SIGNAL CHECK H...

Page 546: ...DI 605 DI 589 DI 573 IN 31 Cruise control not cancelled even when transmission is shifted to N position 1 Cruise Control Cable 2 Park Neutral Position Switch Circuit 3 Actuator Motor Circuit 4 Cruise...

Page 547: ...16 V TC GND C15 5 C15 16 P B W B Ignition switch ON Connect terminals TC and E1 of diagnostic check connector Below 1 V ECT GND L B W B During driving Gear position 3rd 10 16 V ECT GND C15 6 C15 16 L...

Page 548: ...DL GND C15 13 C15 16 L W B Ignition switch ON Throttle valve fully closed Below 1 5 V OD GND B L W B During cruise control driving OD switch ON 10 16 V OD GND C15 14 C15 16 B L W B During cruise contr...

Page 549: ...gine Room J B No 2 J B No 3 3B 3B 1W 7 5 AM2 EE EC EFI Relay B R B R B O E8 E8 8 2 MREL IGSW DI 144 DIAGNOSTICS ENGINE 298 Author Date 2001 SIENNA RM787U ECM Power Source Circuit CIRCUIT DESCRIPTION W...

Page 550: ...en terminals B and E1 of the ECM connectors OK Voltage 9 14 V OK Proceed to next circuit inspection shown on problem symptoms table See page DI 21 NG 2 Check for open in harness and connector between...

Page 551: ...pair or replace harness or connector OK 6 Check IGN fuse PREPARATION Remove the IGN fuse from the instrument panel J B CHECK Check continuity of the IGN fuse OK Continuity NG Check for short in all th...

Page 552: ...agram below when the engine is cranked current flows from terminal ST of the ignition switch to the starter relay coil and also current flows to terminal STA of ECM STA signal When the STA signal and...

Page 553: ...EFI MAIN B MREL 8 E8 B O 1W IK3 7 1 ST2 IG2 AM2 W B W B 1K 7 B R E8 3 2C 9 W EB1 W IC1 W IG1 7 4 1G BA1 1 W BA1 BK Fuel Pump EE 1 2 CIR OPN Relay IGN 3 5 2C 2D 2K F IH1 3 C C B W IH1 11 6 W W GR 2 3 5...

Page 554: ...or replace OK 3 Check circuit opening relay See page SF 66 NG Replace circuit opening relay OK 4 Check voltage between terminal FC of ECM and body ground PREPARATION a Remove the glove compartment See...

Page 555: ...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 and fuel pump fuel pump and body ground See page IN 31 NG Repair or r...

Page 556: ...J B No 3 DIAGNOSTICS ENGINE DI 151 305 Author Date 2001 SIENNA RM787U IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the IACV Intake Air Control Valve in response to the en...

Page 557: ...strument panel b Connect the TOYOTA hand held tester to the DLC3 c Turn the ignition switch ON and TOYOTA hand held tes ter main switch ON d Select the ACTIVE TEST mode on the TOYOTA hand held tester...

Page 558: ...an tool excluding TOYOTA hand held tester 1 Check VSV for ACIS See page SF 71 NG Replace VSV for ACIS OK 2 Check voltage between terminal ACIS of ECM connector and body ground PREPARATION a Remove the...

Page 559: ...DI 154 DIAGNOSTICS ENGINE 308 Author Date 2001 SIENNA RM787U 3 Check for vacuum tank See page SF 62 NG Repair or replace OK Check and replace ECM See page IN 31...

Page 560: ...easured as the output voltage of the mass air flow meter The circuit is constructed so that the platinum hot wire and temperature sensor provide a bridge circuit with the power transistor controlled s...

Page 561: ...ed When troubleshooting it is useful for determining whether the vehicle was running or stopped the engine was warmed up or not the air fuel ratio was lean or rich etc at the time of the malfunction 1...

Page 562: ...ess and connector be tween EFI main relay Marking EFI and mass air flow meter See page IN 31 OK 3 Check voltage between terminal VG of ECM connector and body ground PREPARATION a Remove the glove comp...

Page 563: ...REPARATION Remove the glove compartment See page SF 83 CHECK Check the continuity between terminal E2G of the ECM con nector and body ground OK Continuity 1 or less NG Check and replace ECM See page I...

Page 564: ...ngine speed 1 500 rpm or more 2 trip detection logic a VTA 0 63 V b Mass air flow meter output 1 06 V Mass air flow meter WIRING DIAGRAM Refer to DTC P0100 on page DI 22 INSPECTION PROCEDURE HINT Read...

Page 565: ...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 pot...

Page 566: ...topped the engine warmed up or not the air fuel ratio lean or rich etc at the time of the malfunction 1 Connect OBD II scan tool or TOYOTA hand held tester and read value of intake air temp PREPARATIO...

Page 567: ...on the OBD II scan tool or TOYOTA hand held tester OK Temp value 140 C 284 F or more OK Confirm good connection at sensor If OK replace mass air flow meter NG 3 Check for open in harness or ECM PREPA...

Page 568: ...gnition switch ON CHECK Read temp value on the OBD II scan tool or TOYOTA hand held tester OK Temp value 40 C 40 F OK Replace mass air flow meter NG 5 Check for short in harness or ECM PREPARATION a R...

Page 569: ...n or short in engine coolant temp sensor circuit Open or short in engine coolant temp sensor circuit Engine coolant temp sensor ECM HINT After confirming DTC P0115 use the OBD II scan tool or TOYOTA h...

Page 570: ...l engine coolant temperature HINT If there is open circuit OBD II scan tool or TOYOTA hand held tester indicates 40 C 40 F If there is open circuit OBD II scan tool or TOYOTA hand held tester indicate...

Page 571: ...sual and contact pressure check for the ECM connector See page IN 31 c Turn the ignition switch ON CHECK Read temperature value on the OBD II scan tool or TOYOTA hand held tester OK Temperature value...

Page 572: ...Remove the glove compartment See page SF 83 b Disconnect the E11 connector of the ECM HINT Engine coolant temp sensor connector is disconnected c Turn the ignition switch ON CHECK Read temperature val...

Page 573: ...nt temp sensor Cooling system When THW 35 C 95 F or more and less than 60 C 140 F THA 6 7 C 19 9 F or more when starting engine condition a and b continues a Vehicle speed is changing Not stable b Whe...

Page 574: ...DI 36 DIAGNOSTICS ENGINE 190 Author Date 2001 SIENNA RM787U 2 Check thermostat See page CO 12 NG Replace thermostat OK Replace engine coolant temp sensor...

Page 575: ...ned the ECM judges the vehicle driving conditions from these signals input from terminals VTA and uses them as one of the conditions for deciding the air fuel ratio correction power increase correctio...

Page 576: ...r determining whether the vehicle was running or stopped the engine warmed up or not the air fuel ratio lean or rich etc at the time of the malfunction 1 Connect OBD II scan tool or TOYOTA hand held t...

Page 577: ...ion switch ON CHECK Measure voltage between terminal 1 VC of wire harness side connector and body ground OK Voltage 4 5 5 5 V NG Go to step 5 OK 3 Check throttle position sensor PREPARATION Disconnect...

Page 578: ...3 1 0 V Fully open 2 7 5 2 V NG Check for open and short in harness and con nector between ECM and throttle position sen sor VTA line See page IN 31 OK Check and replace ECM See page IN 31 5 Check vol...

Page 579: ...eed between 30 km h 19 mph and 0 km h 0 mph 2 trip detection logic Throttle position sensor INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Because f...

Page 580: ...or is malfunctioning ECM is unable to per form accurate air fuel ratio control The A F sensor is equipped with a heater which heats the zirconia element The heater is controlled by the ECM When the in...

Page 581: ...C C II2 A J14 J C II2 II2 B W R L B R BR W L W E11 E11 E11 E11 E11 E9 Y G B R II2 B L L R 4 L Heated Oxygen sensor J B No 3 Y G 3 5 IK5 L DIAGNOSTICS ENGINE DI 43 197 Author Date 2001 SIENNA RM787U O...

Page 582: ...E i idli Not remains at 3 3 V 0 660 V Engine idling Not remains at 3 3 V 0 660 V Not remains at 3 8 V 0 76 V or more Driving at engine speed 1 500 rpm or more and vehicle speed 40 km h 25 mph or move...

Page 583: ...pair or replace harness or connector OK 4 Check resistance of A F sensor heaters bank1 2 sensor1 See page SF 81 NG Replace A F sensor OK 5 Check air induction system See page SF 1 NG Repair or replace...

Page 584: ...K Replace A F sensors bank1 2 sensor1 9 Perform confirmation driving pattern See page DI 104 Go 10 Is there DTC P0125 being output again YES Check and replace ECM See page IN 31 NO 11 Did vehicle runs...

Page 585: ...ne coolant temp sensor ECM INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Because freeze frame records the engine conditions when the malfunction is...

Page 586: ...rs to the sensor farther away from the engine body WIRING DIAGRAM Refer to DTC P0125 on page DI 42 INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Be...

Page 587: ...DLC3 b Warm up the engine to normal operating temp CHECK Read voltage output of heated oxygen sensor bank 1 sensor 2 when engine suddenly raced HINT Perform quick racing to 4 000 rpm 3 min using acce...

Page 588: ...M Refer to DTC P0125 on page DI 42 INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Because freeze frame records the engine conditions when the malfun...

Page 589: ...te 2001 SIENNA RM787U 2 Check resistance of heated oxygen sensor heater See page SF 82 NG Replace heated oxygen sensor OK Check and repair harness or connector between EFI main relay Marking EFI heate...

Page 590: ...f both the short term fuel trim and long term fuel trim exceed a certain value it is detected as a malfunction and the MIL lights up DTC No DTC Detecting Condition Trouble Area P0171 P0174 When air fu...

Page 591: ...sors bank 1 2 sensor 1 output voltage which is displayed on the TOYOTA hand held tester INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Because freez...

Page 592: ...4 Check for spark and ignition See page IG 1 NG Repair or replace OK 5 Check fuel pressure See page SF 6 NG Check and repair fuel pump pressure regulator fuel pipe line and filter See page SF 1 OK 6...

Page 593: ...5mph or more and operate throttle valve open and close Not remains at 3 8 V 0 76 V or more Not remains at 2 8 V 0 56 V or less When you use the OBDII scan tool excluding TOYOTA hand held tester HINT D...

Page 594: ...irmation driving pattern See page DI 104 Go 10 Is there DTC P0171 P0172 P0174 or P0175 being output again YES Check and replace ECM See page IN 31 NO 11 Did vehicle runs out of fuel in the past NO Che...

Page 595: ...condition has deteriorated the MIL lights up If the misfire rate is high enough and the driving conditions will cause catalyst overheating the MIL blinks when misfiring occurs DTC No DTC Detecting Con...

Page 596: ...ord DTC and the freeze frame data 3 Use the TOYOTA hand held tester to set to Check Mode See page DI 3 4 Drive the vehicle several times with the engine speed load and its surrounding range shown with...

Page 597: ...misfire See the confirmation driving pattern When either of SHORT FT 1 LONG FT 1 SHORT FT 2 or LONG FT 2 in the freeze frame data is besides the range of 20 there is a possibility that the air fuel ra...

Page 598: ...linder PREPARATION a Remove the glove compartment See page SF 83 b Turn the ignition switch ON CHECK Measure voltage between applicable terminal of the ECM con nector and body ground OK Voltage 9 14 V...

Page 599: ...31 5 Check fuel pressure See page SF 1 NG Check and repair fuel pump fuel pipe line and filter See page SF 1 OK 6 Check injector injection See page SF 26 NG Replace injector OK 7 Check mass air flow...

Page 600: ...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 betwe...

Page 601: ...DLC3 b Disconnect the wire to wire connector EC1 c Connect the terminals of the disconnected EC1 male con nector and EC1 female as follows Male connector Female connector Terminal 1 Terminal 2 Termina...

Page 602: ...ness or connector OK Check and replace ECM See page IN 31 3 Check for open and short in harness and connector between EC1 connector and knock sensor See page IN 31 HINT If DTC P0325 has changed to P03...

Page 603: ...ngine speed by the NE signals DTC No DTC Detecting Condition Trouble Area P0335 No crankshaft position sensor signal to ECM during cranking 2 trip detection logic Open or short in crankshaft position...

Page 604: ...g or idling check between terminals G22 and NE NE and NE of the ECM connector HINT The correct waveforms are as shown NG Replace crankshaft position sensor OK 2 Check for open and short in harness and...

Page 605: ...d the engine speed by the NE signals DTC No DTC Detecting Condition Trouble Area P0340 No camshaft position sensor signal to ECM during cranking 2 trip detection logic Open or short in camshaft positi...

Page 606: ...s and connector between ECM and camshaft position sensor See page IN 31 NG Repair or replace harness or connector OK 3 Inspect sensor installation and tooth of left bank camshaft timing pulley NG Tigh...

Page 607: ...d forth between rich and lean much more slowly When the waveform of the heated oxygen sensor located behind the catalyst alternates flatteringly between rich and lean it indicates that catalyst perfor...

Page 608: ...t 3 000 rpm for 2 sec and 2 000 rpm for 2 sec alternately check the wave form of the heated oxygen sensor bank 1 sensor 2 INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester...

Page 609: ...Author Date 2001 SIENNA RM787U 3 Check A F sensors bank 1 2 sensor 1 See page SF 81 NG Repair or replace OK 4 Check heated oxygen sensor bank 1 sensor 2 See page SF 82 NG Repair or replace OK Replace...

Page 610: ...ntrol system based on the vapor pressure sensor signal DTC P0440 or P0442 is recorded by the ECM when evaporative emissions leak from the components within the dotted line in Fig 1 below or when the v...

Page 611: ...r P0451 If no malfunction is detected troubleshoot DTC P0440 or P0442 next Ask the customer whether after the MIL came on the customer found the fuel tank cap loose and tight ened it Also ask the cust...

Page 612: ...cks deformation and loose connection of the fol lowing parts Fuel tank Charcoal canister Fuel tank filler pipe Hoses and tubes around fuel tank and charcoal canister NG Repair or replace OK 2 Check th...

Page 613: ...switching valve and charcoal 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 dam...

Page 614: ...tment See page SF 83 b Turn the ignition switch ON CHECK Measure the voltage between terminals VC and E2 of the ECM connector OK Voltage 4 5 5 5 V NG Check and replace ECM See page IN 31 OK 10 Check v...

Page 615: ...page IN 31 NG Repair or replace harness or connector OK Replace vapor pressure sensor 12 Check fuel tank and fuel tank over fill check valve for cracks and damage NG Replace fuel tank or fuel tank ov...

Page 616: ...SCRIPTION The vapor pressure sensor VSV for canister closed valve CCV VSV for pressure switching valve are used to detect abnormalities in the evaporative emission control system The ECM decides wheth...

Page 617: ...d fuel tank is maintained at atmospheric pressure 2 trip detec tion logic VSV for pressure switching valve Fuel tank cracked holed or damaged Charcoal canister cracked holed or damaged Fuel tank over...

Page 618: ...ce fuel tank cap OK 5 Check filler neck for damage See page DI 72 NG Replace filler pipe OK 6 Check vacuum hoses between vapor pressure sensor and fuel tank charcoal canister and VSV for pressure swit...

Page 619: ...ctor OK 9 Check vacuum hoses 8 9 10 and 11 in Fig 1 in circuit description CHECK a Check that the vacuum hose is connected correctly b Check the vacuum hose for looseness and disconnection c Check the...

Page 620: ...ester c Disconnect the vacuum hose for the VSV for the EVAP from the charcoal canister d Start the engine CHECK When the VSV for the EVAP is operated by the TOYOTA hand held tester check whether the d...

Page 621: ...ter 16 Check for open and short in harness and connector between EFI main relay Marking EFI and VSV for EVAP and VSV for EVAP and ECM See page IN 31 NG Repair or replace harness or connector OK Check...

Page 622: ...ly b Check the vacuum hose for looseness and disconnection c Check the vacuum hose for cracks hole damage and blockage NG Repair or replace OK 19 Check operation of VSV for CCV See page SF 73 OK Go to...

Page 623: ...erated by the TOYOTA hand held tester OK VSV is ON Air from port E flows out through port F VSV is OFF Air does not flow from port E to port F OK Go to step 24 NG 22 Check operation of VSV for pressur...

Page 624: ...on the TOYOTA hand held tester d Start the engine e The VSV for the CCV is ON by the TOYOTA hand held tester f The VSV for the EVAP and the VSV for the pressure switching valve are ON by the TOYOTA h...

Page 625: ...ure switching valve are ON by the TOYOTA hand held tester f The VSV for the EVAP is ON by the TOYOTA hand held tester and hold the VSV for the EVAP until voltage be tween terminals PTNK and E2 becomes...

Page 626: ...hether there are signs of any accident near fuel tank or charcoal canister See page DI 72 NG Repair or replace OK 2 Check that fuel tank cap is TOYOTA genuine parts See page DI 72 NG Replace to TOYOTA...

Page 627: ...etween fuel tank and charcoal canister See page DI 72 NG Repair or replace OK 8 Check VSV connector for EVAP VSV connector for CCV VSV connector for pres sure switching valve and vapor pressure sensor...

Page 628: ...e DI 72 NG Check and replace ECM See page IN 31 OK 11 Check voltage between terminals PTNK and E2 of ECM connectors See page DI 72 OK Go to step 13 NG 12 Check for open and short in harness and connec...

Page 629: ...e ECM connector and body ground OFF OK 1 VSV is ON Air from port E frows out through port F 2 VSV is OFF Air does not flow from port E to port F OK Go to step 16 NG 14 Check operation of VSV for EVAP...

Page 630: ...nd body ground ON 2 Disconnect between terminal CCV of the ECM con nector and body ground OFF 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 O...

Page 631: ...n terminal TBP of the ECM con nector 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 22 NG 20 Check opera...

Page 632: ...RM787U NG Repair or replace harness or connector OK Check and replace ECM See page IN 31 22 Check fuel tank over fill check valve See page EC 6 NG Replace fuel tank over fill check valve or fuel tank...

Page 633: ...e ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sen...

Page 634: ...mining whether the vehicle was running or stopped the engine was warmed up or not the air fuel ratio was lean or rich etc at the time of the malfunction When the ENGINE RUN TIME in the freeze frame da...

Page 635: ...meter After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit in side the combination meter it is then transmitted to the ECM The ECM determines the ve...

Page 636: ...at the time of the malfunction 1 Check operation of speedometer CHECK Drive the vehicle and check if the operation of the speedometer in the combination meter is normal HINT The vehicle speed sensor...

Page 637: ...he E9 connector of ECM CHECK Measure voltage between terminal SPD of the ECM connector and body ground OK Voltage 9 14 V NG Check for open in harness and connector between junction connector J B No 3...

Page 638: ...rotary solenoid type IAC valve is located in front of the in take air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage In this way the intake air vol...

Page 639: ...an or rich etc at the time of the malfunction 1 Check engine idle speed PREPARATION a Warm up engine to normal operating temperature b Switch off all accessories c Switch off air conditioning d Shift...

Page 640: ...E12 connector of ECM c Turn the ignition switch ON CHECK Measure voltage between terminals RSO RSC of the ECM connector and body ground OK Voltage 9 14 V OK Go to step 4 NG 3 Check IAC valve See page...

Page 641: ...5 Check the blockage of IAC valve and the passage to bypass the throttle valve NG Repair or replace IAC valve OK Check and replace ECM See page IN 31 6 Check for A C signal circuit See page AC 133 NG...

Page 642: ...hort in A F sensors bank 1 2 sensor 1 circuit A F sensors bank 1 2 sensor 1 ECM Open or short in A F sensor circuit 2 trip detection logic HINT After confirming DTCs P1130 or P01150 use the OBD II sca...

Page 643: ...ly followed detection of the malfunction will not be possible If you do not have a TOYOTA hand held tester turn the ignition switch OFF after performing steps 3 and 4 then perform steps 3 and 4 again...

Page 644: ...ins at 3 30 V 0 660 V Not remains at 3 8 V 0 76 V or more Driving at engine speed 1 500 rpm or more and vehicle speed 40 km h 25 mph or more and operate throttle valve open and close Not remains at 3...

Page 645: ...ors bank 1 2 sensor 1 See page IN 31 NG Repair or replace harness or connector OK 4 Check resistance of A F sensor heater See page SF 81 NG Replace A F sensor OK 5 Check air induction system See page...

Page 646: ...eplace A F sensors bank1 2 sensor1 8 Perform confirmation driving pattern Go 9 Are there DTC P1130 and or P1150 being output again YES Check and replace ECM See page IN 31 NO 10 Did vehicle runs out o...

Page 647: ...km h 38 mph or more if response characteristic of A F sensor becomes deteriorated 2 trip detection logic A F sensors bank 1 2 sensor 1 INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA han...

Page 648: ...ains at 3 30 V 0 660 V Not remains at 3 8 V 0 76 V or more Driving at engine speed 1 500 rpm or more and vehicle speed 40 km h 25 mph or more and operate throttle valve open and close Not remains at 3...

Page 649: ...sors bank 1 2 sensor 1 See page IN 31 NG Repair or replace harness or connector OK 4 Check resistance of A F sensor heater See page SF 81 NG Replace A F sensor OK 5 Check air induction system See page...

Page 650: ...A F sensors bank1 2 sensor1 8 Perform confirmation driving pattern See page DI 104 Go 9 Are there DTC P1133 and or P1153 being output again YES Check and replace ECM See page DI 3 NO 10 Did vehicle ru...

Page 651: ...k 1 2 sensor 1 heater ECM WIRING DIAGRAM Refer to DTC P0125 on page DI 42 INSPECTION PROCEDURE HINT Read freeze frame data using TOYOTA hand held tester or OBD II scan tool Because freeze frame record...

Page 652: ...RM787U 2 Check resistance of A F sensor heaters bank 1 2 sensor 1 See page SF 81 NG Replace A F sensors bank 1 2 sensor 1 OK Check and repair harness or connector between EFI main relay Marking EFI an...

Page 653: ...ing High voltage generated in the secondary winding is applied directly to the spark plug The spark of the spark plug pass from the center elecrtode to the ground electrode The ECM determines ignition...

Page 654: ...tion Coil and Igniter No 6 W B W B W B 4 2 1 3 I5 Ignition Coil and Igniter No 5 L W W B 4 2 1 3 B B B B I4 Ignition Coil and Igniter No 4 B R W B W B B 4 2 1 3 W R W B I3 Ignition Coil and Igniter No...

Page 655: ...re output simultaneously IGF1 circuit may be open or short If DTCs P1305 P1310 and P1320 are output simultaneously IGF2 circuit may be open or short Read freeze frame data using TOYOTA hand held teste...

Page 656: ...84 b Disconnect the ignition coil with the igniter connector c Turn the ignition switch ON CHECK Measure the voltage between terminals IGF of the ECM con nector and body ground OK Voltage 4 5 5 5 V O...

Page 657: ...n 4 5 V Reference INSPECTION USING OSCILLOSCOPE During cranking or idling check the waveform between termi nals IGT1 IGT6 and E1 of the ECM connector HINT Correct waveform appears as shown with rectan...

Page 658: ...round when the ignition switch is turned to ON and START position OK Voltage 9 14 V NG Repair ignition coil with igniter power source circuit OK 8 Check for open and short in harness and connector bet...

Page 659: ...rt in crankshaft position sensor circuit Crankshaft position sensor Starter ECM WIRING DIAGRAM Refer to DTC P0335 on page DI 65 INSPECTION PROCEDURE Read freeze frame data using TOYOTA hand held teste...

Page 660: ...iation in crankshaft position sensor signal and VVT sensor bank 2 signal 2 trip detection logic belt stretched ECM WIRING DIAGRAM Refer to DTC P335 on page DI 65 INSPECTION PROCEDURE HINT Read freeze...

Page 661: ...angle has been achieved by monitoring the camshaft position sensor DTC No DTC Detecting Condition Trouble Area P1349 P1354 Condition a or b continues for after the engine is warmed up and engine speed...

Page 662: ...tem is OK DTCs P1349 and P1354 are also output after the foreign ob ject is caught in some part of the system in the engine oil and the system returns to normal in a short time As ECM controls so that...

Page 663: ...d Drain oil into the VVT controller assembly See page EM 33 CHECK Check whether the oil into VVT controller assembly is drained or not OK The oil into VVT controller assembly is drained NG Replace VVT...

Page 664: ...OK DTCs P1349 and P1354 are also output after the foreign ob ject is caught in some part of the system in the engine oil and the system returns to normal in a short time As ECM controls so that forei...

Page 665: ...ltage between terminals OCV and OCV of ECM connector Reference INSPECTION USING OSCILLOSCOPE Turn the ignition switch ON check the waveform between termi nals OCV and OCV of the ECM connector HINT The...

Page 666: ...V See page EM 33 d Drain oil into the VVT controller assembly See page EM 33 CHECK Check whether the oil into VVT controller assembly is drained or not OK The oil into VVT controller assembly is drain...

Page 667: ...ge DI 3 OK DTC P1349 P1354 is not stored OK VVT system is OK DTCs P1349 and P1354 are also output after the foreign ob ject is caught in some part of the system in the engine oil and the system return...

Page 668: ...Camshaft position sensor signal to ECM with 5 sec or more engine speed 600 rpm or more cuit VVT sensor camshaft position sensor Camshaft timing gear P1350 While crankshaft rotates twice VVT sensor Cam...

Page 669: ...short in harness and connector between ECM and VVT sen sor See page IN 31 NG Repair or replace harness or connector OK 3 Inspect sensor installation and signal plate teeth of camshaft timing gear NG T...

Page 670: ...gnal is used to detect when the brakes have been applied The STP signal voltage is the same as the voltage supplied to the stop lights The STP signal is used mainly to control the fuel cut off engine...

Page 671: ...Check if the stop lights go on and off normally when the brake pedal is operated and released NG Check and repair stop light circuit OK 2 Check STP signal When using TOYOTA hand held tester PREPARATIO...

Page 672: ...NOSTICS ENGINE 288 Author Date 2001 SIENNA RM787U 3 Check harness and connector between ECM and stop light switch See page IN 31 NG Repair or replace harness or connector OK Check and replace ECM See...

Page 673: ...No DTC Detecting Condition Trouble Area P1600 Open in back up power source circuit Open in back up power source circuit ECM HINT If DTC P1600 appear the ECM does not store another DTC WIRING DIAGRAM...

Page 674: ...F 83 CHECK Measure voltage between terminal BATT of the ECM connector and body ground OK Voltage 9 14 V OK Check and replace ECM See page IN 31 NG 2 Check EFI fuse PREPARATION Remove the EFI fuse from...

Page 675: ...hand held tester or OBD II scan tool Because freeze frame records the engine conditions when the malfunction is detected When troubleshooting it is useful for determining whether the vehicle was runn...

Page 676: ...ge between terminals of the OCV CHECK Check the engine speed OK Rough idle or engine stalled NG Replace OCV OK 3 Check voltage between terminals OCV and OCV of ECM connector See page DI 123 NG Check a...

Page 677: ...ply 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 voltage between terminals OCV and OCV of ECM connector...

Page 678: ...tches are ON simultaneously for N 2 L and R positions 2 trip detection logic Sh t i k t l iti it h i it P1780 When driving under conditions a and b for 30 sec or more the park neutral position switch...

Page 679: ...No 1 J7 DIAGNOSTICS ENGINE DI 141 295 Author Date 2001 SIENNA RM787U Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked the intake air flow is slow so fuel vaporization is poor A ri...

Page 680: ...al 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 CHECK Read STA signal on the TOYOTA hand held tester...

Page 681: ...e glove compartment See page SF 83 CHECK Measure voltage between terminal STA of the ECM connector and body ground during engine cranking OK Voltage 6 V or more OK Proceed to next circuit inspection s...

Page 682: ...m N to D Other Dates Problem Occurred Problem Frequency Condition When Problem Occurs Weather Engine Operation Engine Temperature Place Outdoor Temperature Constant Sometimes times per day month Once...

Page 683: ...Malfunction Open or short in engine coolant temp sensor circuit Engine coolant temp sensor ECM P0116 DI 35 Engine Coolant Temp Circuit Range Performance Problem Engine coolant temp sensor Cooling sys...

Page 684: ...sor 1 circuit Knock sensor 1 looseness ECM 1 P0330 DI 62 Knock Sensor 2 Circuit Malfunction Open or short in knock sensor 2 circuit Knock sensor 2 looseness ECM 1 P0335 DI 65 Crankshaft Position Senso...

Page 685: ...Speed Sensor Malfunction Open or short in speed sensor circuit Vehicle speed sensor Combination meter ECM P0505 DI 100 Idle Control System Malfunction IAC valve is stuck or closed Open or short in IA...

Page 686: ...n coil with igniter to ECM No 6 ignition coil with igniter ECM P1335 DI 121 Crankshaft Position Sensor Circuit Malfunction during engine running Open or short in crankshaft position sensor circuit Cra...

Page 687: ...sition switch circuit Park neutral position switch ECM B2795 DI 621 Unmatched key Code Immobiliser system B2796 DI 622 No Communication in Immobiliser System Immobiliser system B2797 DI 624 Communicat...

Page 688: ...ymptom Simulation P IN 21 DTC Chart P DI 13 Problem Symptoms Table P DI 21 Circuit Inspection P DI 22 Adjustment Repair DTC Check P DI 3 Titles inside are titles of pages in in the bottom portion See...

Page 689: ...ture sensor A F Sensor Bank 1 Sensor 1 Knock Sensor 1 Vapor Pressure Sensor Charcoal Canister VSV for Pressure Switching Valve VSV for Canister Closed Valve CCV Park Neutral Position Switch A F Sensor...

Page 690: ...n in the computer In addition to the MIL lighting up when a malfunction is detected the ap plicable Diagnostic Trouble Codes DTC pre scribed by SAE J2012 are recorded in the ECM memory See page DI 13...

Page 691: ...OFF between the 1st trip and the 2nd trip Freeze frame data Freeze frame data records the engine condition when a misfire DTCs P0300 P0306 or fuel trim malfunction DTCs P0171 P0172 P0174 P0175 or othe...

Page 692: ...ed to another vehicle inspect DLC3 on the original vehicle 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 t...

Page 693: ...eat the simulation process again When the problem has been simulated twice the MIL lights up and the DTCs are recorded in the ECM Check the 1st trip DTC using Mode 7 Continuous Test Results for SAE J1...

Page 694: ...CE If the TOYOTA hand held tester switches the ECM from normal mode to check mode or vice versa or if the igni tion switch is turned from ON to ACC or OFF during check mode the DTC and freezed frame d...

Page 695: ...e ignitions 5 CHECK FOR INTERMITTENT PROBLEMS TOYOTA HAND HELD TESTER only By putting the vehicle s ECM in check mode 1 trip detection logic is possible instead of 2 trip detection logic and sensitivi...

Page 696: ...e to trouble shoot YES 3 Does engine start NO Go to step 7 YES 4 Check air filter PREPARATION Remove the air filter CHECK Visually check that the air filter is not dirty or excessive oily HINT If nece...

Page 697: ...ion timing See page EM 10 NG Proceed to page IG 1 and continue to trouble shoot OK Proceed to problem symptoms table on page DI 21 7 Check fuel pressure See page SF 6 NG Proceed to page SF 6 and conti...

Page 698: ...ce Ignition Timing of Cylinder No 1 Idling BTDC 8 12 INTAKE AIR Intake Air Temp Sensor Value Equivalent to Ambient Temp MAF Air Flow Rate Through Mass Air Flow Meter Idling 3 3 4 7 gm sec Racing witho...

Page 699: ...N CYL 1 CYL 6 Abnormal revolution variation for each cylinder 0 IGNITION Total number of ignition for every 1 000 revolu tions 0 3 000 INTAKE CTRL VSV Intake Air Control Valve VSV Signal VSV operating...

Page 700: ...nal circuit 2 Fuel pump control circuit DI 141 DI 147 High engine idle speed Poor idling 1 A C signal circuit Compressor Circuit Manual A C Auto A C 2 ECM power source circuit AC 133 DI 776 DI 144 Low...

Page 701: ...1 16 NE E11 24 B W W Idling Pulse generation See page DI 130 OC1 E12 6 OC1 E12 5 R B L B P l ti OC2 E12 29 OC2 E12 18 R B W IG switch ON Pulse generation See page DI 123 THA E11 22 E2 E11 18 L Y W Idl...

Page 702: ...1 W R W B IG switch ON Disconnect vacuum hose from VSV for pressure switching valve 9 14 PTNK E8 17 E1 E11 17 L R BR IG switch ON 2 9 3 7 PTNK E8 17 E1 E11 17 L R BR IG switch ON Apply vacuum 4 0 kPa...

Page 703: ...M2 2 3 5 1 DIAGNOSTICS ENGINE IMMOBILISER SYSTEM DI 615 769 Author Date 2001 SIENNA RM787U CIRCUIT INSPECTION DTC B2785 99 IG Switch ON Malfunction DTC B2786 99 IG Switch OFF Malfunction CIRCUIT DESCR...

Page 704: ...ment b Turn ignition switch ON CHECK Measure voltage between terminals B and E1 of ECM con nectors OK Voltage 9 14 V OK Proceed to next circuit inspection shown in problem symptoms See page DI 614 NG...

Page 705: ...EFI fuse OK 5 Check for open harness and connector between EFI main relay Marking EFI and battery EFI main relay Marking EFI and ECM See page IN 31 NG Repair or replace harness or connector OK 6 Chec...

Page 706: ...M787U 7 Check ignition switch See page BE 15 NG Replace ignition switch OK 8 Check for open circuit in harness and connector between ignition switch and EFI main relay EFI main relay and body ground S...

Page 707: ...ILISER SYSTEM DI 619 773 Author Date 2001 SIENNA RM787U DTC B2791 99 Key Unlock Warning SW OFF Malfunction CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area B2791 99 Open circuit in key...

Page 708: ...2001 SIENNA RM787U INSPECTION PROCEDURE 1 Check key unlock warning switch See page BE 15 NG Replace key unlock warning switch OK 2 Check harness and connector between key unlock warning switch and ECM...

Page 709: ...lete DTC and insert the key that a customer keeps to check that B2795 is output When a key that outputs B2795 is found register this key When B2795 is not output there is a possibility that the unregi...

Page 710: ...NOSTICS ENGINE IMMOBILISER SYSTEM 776 Author Date 2001 SIENNA RM787U DTC B2796 99 No Communication in Immobiliser system CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area B2796 99 No com...

Page 711: ...nsponder key coil See page BE 159 NG Replace transponder key coil OK 2 Check harness and connector between transponder key amplifier and ECM NG Repair or replace harness and connector OK 3 Does it ope...

Page 712: ...RM787U DTC B2797 99 Communication Malfunction No 1 CIRCUIT DESCRIPTION This code is detected when although the communication has been performed normally an error occurs Example Some noise is incluede...

Page 713: ...gistered master key in the key cylinder CHECK Using an oscilloscope or TOYOTA hand held tester check that noise is included in the CODE terminal of ECM OK No noise is detected NG Try to find the cause...

Page 714: ...IAGNOSTICS ENGINE IMMOBILISER SYSTEM 780 Author Date 2001 SIENNA RM787U DTC B2798 99 Communication malfunction No 2 CIRCUIT DESCRIPTION DTC No DTC Detecting Condition Trouble Area B2798 99 Communicati...

Page 715: ...nsponder key coil See page BE 159 NG Replace transponder key coil OK 2 Check harness and connector between transponder key amplifier and ECM NG Repair or replace harness and connector OK 3 Does it ope...

Page 716: ...ttently times a day DTC Check 1st Time 2nd Time Normal Code Malfunction Code Code Normal Code Malfunction Code Code Symptoms km miles Engine does not start Check Item Malfunction Indicator Light Norma...

Page 717: ...g switch Main Relay Wireharness B2795 99 DI 621 Unmatched key code Key Unregistered key inserted before B2796 99 DI 622 No communication in immobiliser system Key Transponder key coil Amplifier Wireha...

Page 718: ...nd part Inspection DTC Chart Malfunction code Problem Symptoms Table Identification of Problem Normal code Repair Confirmation Test End 1 2 3 4 5 6 7 8 9 10 Step 2 5 Diagnostic steps permitting the us...

Page 719: ...8871 Engine Room J B No 2 EFI Fuse Transponder Key Amplifier Transponder Key Coil ECM IGN Fuse Instrument Panel J B DI 612 DIAGNOSTICS ENGINE IMMOBILISER SYSTEM 766 Author Date 2001 SIENNA RM787U PART...

Page 720: ...with SAEJ1962 and matches the ISO 9141 2 format Tester connection condition Specified condition 7 Bus Line 5 Signal ground During communication Pulse generation 4 chassis Ground Body Always 1 or less...

Page 721: ...OBD ll scan tool or TOYOTA hand held tester to check the DTCs and freeze frame data note them down For operating instructions see the OBD ll scan tool s instruction book 5 See page DI 61 1 to confirm...

Page 722: ...check disconnect terminals 13 TC and 4 CG and turn OFF the display HINT In the event of 2 or more malfunction codes indication will begin from the smaller numbered code and continue in order to the l...

Page 723: ...has been registered in the automatic registration mode indicator is not OFF 1 Wire harness 2 Transponder key coil 3 Amplifier 4 ECM IN 31 BE 159 IN 31 Security indicator is OFF When DTC of immobiliser...

Page 724: ...IENNA RM787U TERMINALS OF ECM Symbols Terminals No Wiring Color Condition STD Voltage V CODE E1 E9 28 E11 17 BR W BR Ignition Switch ON 10 14 TXCT E1 E9 18 E11 17 BR Y BR Ignition Switch ON 10 14 KSW...

Page 725: ...detection by the controller Power opera tion is inhibited until this code has been reset DTC No DTC Detecting Condition Trouble Area 1 3 Controller detects a position count past the ends of travel li...

Page 726: ...ESCRIPTION If this code is detected the power slide door stops Power operation will be retried on the next command DTC No Detection Item Trouble Area 1 4 Failure is detected in the motor drive circuit...

Page 727: ...retried on each OPEN CLOSE command DTC No DTC Detecting Condition Trouble Area 2 2 Sensor pulses are not detected upon motor activation Power slide door unit Optical sensor INSPECTION PROCEDURE 1 Che...

Page 728: ...STEM 668 Author Date 2001 SIENNA RM787U DTC 2 3 No Secondary Latch Input CIRCUIT DESCRIPTION This code remains set until the door is detected to be fully closed Power close operation is possible when...

Page 729: ...CTION PROCEDURE 1 Check latch switch See page BE 78 NG Replace the latch switch OK 2 Check wire harness and connector between latch switch and power slide door ECU latch switch and body ground See pag...

Page 730: ...Continuously Intermittently times a day DTC Check 1st Time 2nd Time Normal Code Malfunction Code Code Normal Code Malfunction Code Code Problem km miles Sliding roof operates abnormally or stops half...

Page 731: ...IENNA RM787U DIAGNOSTIC TROUBLE CODE CHART DTC No See Page Detection Item Trouble Area 1 2 Normal 1 3 DI 511 Door position out of range Drive Unit 1 4 DI 512 Motor drive circuit ECU 2 2 DI 513 No opti...

Page 732: ...IN 31 Symptom occur DTC Check Pre check P DI 503 DTC Chart P DI 506 Confirmation Test Problem Symptoms Table P DI 510 Circuit Inspection P DI 511 DI 514 Code 1 2 Except Code 1 2 DIAGNOSTICS POWER SLID...

Page 733: ...itch Power Slide Door MAIN Switch Engine Room J B No 2 Latch Switch Power Slide Door Control ECU Power Slide Door Control Unit Power Slide Door Control ECU Latch Switch Power Slide Door Control Switch...

Page 734: ...meter See page BE 2 Even if RH or LH slide door is closed when the PWR DOOR indicator light does not go OFF initialize the pow er slide door control system b Check the mode 1 HINT In this mode DTC can...

Page 735: ...ower slide door control switch for more than 4 secs 2 PWR DOOR indicator flushes 3 times for 3 secs and the mode is transferred to mode 3 3 When pushing the control switch ON with the RH or LH side do...

Page 736: ...DIAGNOSTICS POWER SLIDE DOOR CONTROL SYSTEM DI 505 659 Author Date 2001 SIENNA RM787U f Repeat the step d and e...

Page 737: ...S TABLE Symptom Suspect Area See page Power slide door does not operate 1 Power slide door MAIN switch 2 Power slide door unit 3 Fuel lid courtesy LH side only 4 Wire harness 5 Power slide door ECU BE...

Page 738: ...h ACC or ON and shift lever except P position Below 1 0 CSW GND G Y W B Power slide door control switch ON 10 14 CSW GND S32 5 S31 1 G Y W B Power slide door control switch OFF Below 2 0 DSW GND G W B...

Page 739: ...ON 10 14 CSW GND S30 5 S29 1 G B W B Power slide door control switch OFF Below 2 0 DSW GND G W B Latch switch ON 1 Below 2 0 DSW GND S30 6 S29 1 G W B Constant 10 14 MSW GND S30 8 S29 1 BR B W B Powe...

Page 740: ...g 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...

Page 741: ...page DI 486 2 Check D squib circuit PREPARATION Release the airbag activation prevention mechanism of the connector on the airbag sensor assembly side between the airbag sensor assembly and the spira...

Page 742: ...al cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignit...

Page 743: ...CK a Turn the ignition switch to LOCK and wait at least for 20 seconds b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn...

Page 744: ...measure the resistance be tween D and D OK Resistance 1 M or Higher NG Repair or replace spiral cable OK 6 Check harness between airbag sensor assembly and spiral cable PREPARATION Release the airbag...

Page 745: ...2 DTC B0101 14 is recorded when an open is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0101 14 Open circuit in D wire harness or D wire harness of squib D squib malfun...

Page 746: ...ide between the spiral cable and the steering wheel pad c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least for...

Page 747: ...ttery and wait at least for 2 seconds CHECK a Turn ignition switch to ACC or ON and wait at least for 20 seconds b Clear DTC stored in memory See page DI 358 c Turn ignition switch to LOCK and wait at...

Page 748: ...able and the steering wheel pad measure the resistance be tween D and D OK Resistance Below 1 NG Repair or replace spiral cable OK 6 Check harness between airbag sensor assembly and spiral cable CHECK...

Page 749: ...B0102 11 is recorded when a ground short is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0102 11 Short circuit in D squib wire harness to ground D squib malfunction Sp...

Page 750: ...the spiral cable and the steering wheel pad c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 sec...

Page 751: ...CC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to A...

Page 752: ...ground OK Resistance 1 M or Higher NG Repair or replace spiral cable OK 6 Check harness between airbag sensor assembly and spiral cable CHECK For the connector on the spiral cable side between the sp...

Page 753: ...B0103 12 is recorded when a B short is detected in the D squib circuit DTC No DTC Detecting Condition Trouble Area B0103 12 Short circuit in D squib wire harness to B D squib malfunction Spiral cable...

Page 754: ...e spiral cable and the steering wheel pad c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 second...

Page 755: ...CC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to A...

Page 756: ...pad measure the volt age between D and body ground OK Voltage 0 V NG Repair or replace spiral cable OK 6 Check harness between airbag sensor assembly and spiral cable CHECK a Turn the ignition switch...

Page 757: ...airbag assembly 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 s...

Page 758: ...tion mechanism of the connector on the airbag sensor assembly side between the front passenger airbag assembly and the airbag sensor assem bly See page DI 358 CHECK For the connector on the front pass...

Page 759: ...e to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition swi...

Page 760: ...rn the ignition switch to LOOK and wait at least for 20 seconds b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn the ign...

Page 761: ...circuit DTC No DTC Detecting Condition Trouble Area B0106 54 Open circuit in P wire harness or P wire harness of squib P squib malfunction Airbag sensor assembly malfunction Front passenger airbag as...

Page 762: ...ont passenger airbag assembly and the airbag sen sor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at...

Page 763: ...at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wait at l...

Page 764: ...quib circuit DTC No DTC Detecting Condition Trouble Area B0107 51 Short circuit in P squib wire harness to ground P squib malfunction Airbag sensor assembly malfunction Front passenger airbag assembly...

Page 765: ...assenger airbag assembly and the airbag sen sor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at leas...

Page 766: ...N and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC or O...

Page 767: ...cuit DTC No DTC Detecting Condition Trouble Area B0108 52 Short circuit in P squib wire harness to B P squib malfunction Airbag sensor assembly malfunction Front passenger airbag assembly P squib Airb...

Page 768: ...assenger airbag assembly and the airbag sen sor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at leas...

Page 769: ...N and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC or O...

Page 770: ...irbag 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...

Page 771: ...irbag activation prevention mechanism of the connector on the airbag sensor assembly side between the airbag sensor assembly and the side airbag assembly RH See page DI 358 CHECK For the connector on...

Page 772: ...le to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition sw...

Page 773: ...a Turn the ignition switch to LOOK and wait at least for 20 second b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn the...

Page 774: ...e squib RH circuit DTC No DTC Detecting Condition Trouble Area B0111 44 Open circuit in SFR wire harness or SFR wire harness of squib Side squib RH malfunction Airbag sensor assembly malfunction Side...

Page 775: ...side airbag assembly RH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at leas...

Page 776: ...nd wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wa...

Page 777: ...ed in the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0112 41 Short circuit in side squib RH wire harness to ground Side squib RH malfunction Airbag sensor assembly malfunction...

Page 778: ...airbag assembly RH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for...

Page 779: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 780: ...the side squib RH circuit DTC No DTC Detecting Condition Trouble Area B0113 42 Short circuit in side squib RH wire harness to B Side squib RH malfunction Airbag sensor assembly malfunction Side airbag...

Page 781: ...nt side airbag assembly RH and the airbag sensor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at lea...

Page 782: ...CC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to A...

Page 783: ...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...

Page 784: ...irbag activation prevention mechanism of the connector on the airbag sensor assembly side between the airbag sensor assembly and the side airbag assembly LH See page DI 358 CHECK For the connector on...

Page 785: ...le to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition sw...

Page 786: ...CK a Turn the ignition switch to LOOK and wait at least for 20 second b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn t...

Page 787: ...side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0116 48 Open circuit in SFL wire harness or SFL wire harness of squib Side squib LH malfunction Airbag sensor assembly malfunction Si...

Page 788: ...side airbag assembly LH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least fo...

Page 789: ...wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wait...

Page 790: ...ed in the side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0117 45 Short circuit in side squib LH wire harness to ground Side squib LH malfunction Airbag sensor assembly malfunction...

Page 791: ...de airbag assembly LH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least f...

Page 792: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 793: ...he side squib LH circuit DTC No DTC Detecting Condition Trouble Area B0118 46 Short circuit in side squib LH wire harness to B Side squib LH malfunction Airbag sensor assembly malfunction Side airbag...

Page 794: ...airbag assembly LH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for...

Page 795: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 796: ...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 d...

Page 797: ...ag activation prevention mechanism of the connector on the airbag sensor assembly side between the airbag sensor assembly and the seat belt pretensioner RH See page DI 358 CHECK For the connector on t...

Page 798: ...able to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition...

Page 799: ...K a Turn the ignition switch to LOOK and wait at least for 20 second b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn th...

Page 800: ...in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0131 64 Open circuit in PR wire harness or PR wire harness of squib P T squib RH malfunction Airbag sensor assembly malfunction...

Page 801: ...seat belt pretensioner RH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at le...

Page 802: ...wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wait...

Page 803: ...ted in the P T squib RH circuit DTC No DTC Detecting Condition Trouble Area B0132 61 Short circuit in P T squib RH wire harness to ground P T squib RH malfunction Airbag sensor assembly malfunction Se...

Page 804: ...belt pretensioner RH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least f...

Page 805: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 806: ...squib RH circuit DTC No DTC Detecting Condition Trouble Area B0133 62 Short circuit in seat belt pretensioner RH wire harness to B P T squib RH malfunction Airbag sensor assembly malfunction Seat bel...

Page 807: ...belt pretensioner RH and the airbag sensor assem bly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least f...

Page 808: ...r ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC o...

Page 809: ...oner 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 d...

Page 810: ...ag activation prevention mechanism of the connector on the airbag sensor assembly side between the airbag sensor assembly and the seat belt pretensioner LH See page DI 358 CHECK For the connector on t...

Page 811: ...able to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition...

Page 812: ...K a Turn the ignition switch to LOOK and wait at least for 20 second b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Clear the DTC stored in memory See page DI 358 d Turn th...

Page 813: ...in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0136 74 Open circuit in PL wire harness or PL wire harness of squib P T squib LH malfunction Airbag sensor assembly malfunctio...

Page 814: ...e seat belt pretensioner LH and the airbag sensor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at le...

Page 815: ...wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wait...

Page 816: ...ted in the P T squib LH circuit DTC No DTC Detecting Condition Trouble Area B0137 71 Short circuit in P T squib LH wire harness to ground P T squib LH malfunction Airbag sensor assembly malfunction Se...

Page 817: ...t belt pretensioner LH and the airbag sensor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least f...

Page 818: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 819: ...squib LH circuit DTC No DTC Detecting Condition Trouble Area B0138 72 Short circuit in seat belt pretensioner LH wire harness to B P T squib LH malfunction Airbag sensor assembly malfunction Seat bel...

Page 820: ...t belt pretensioner LH and the airbag sensor assembly c Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least f...

Page 821: ...or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC...

Page 822: ...ction in the airbag sensor assembly is detected DTC No DTC Detecting Condition Trouble Area B1100 31 Airbag sensor assembly malfunction Airbag sensor assembly INSPECTION PROCEDURE HINT When a malfunct...

Page 823: ...CK a Turn the ignition switch to LOCK and wait at least for 20 seconds b Turn the ignition switch to ACC or ON and wait at least for 20 seconds c Repeat operation in step a and b at least 5 times d Ch...

Page 824: ...RH consists of the safing sensor diagnosis circuit and lateral decelera tion sensor etc It receives signals from the lateral deceleration sensor judges whether or not the SRS must be activated and det...

Page 825: ...age DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC or ON and wait at least for 20 seconds e Check the DTC See page DI 358 HINT Codes other...

Page 826: ...nector b Using a service wire connect SSR and ESR of the con nector on the side airbag sensor assembly side between the side airbag sensor assembly RH and airbag sensor assembly CHECK For the connect...

Page 827: ...connect VUPR and FSR of the connector on the side airbag sensor assembly side between the side air bag sensor assembly RH and airbag sensor assembly CHECK For the connector on the airbag sensor assemb...

Page 828: ...sembly RH and the airbag sensor assembly measure the resistance between body ground and each of SSR VUPR and FSR OK Resistance Below 1 NG Repair or replace harness or connector be tween side airbag se...

Page 829: ...t least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and w...

Page 830: ...onnec tor and connect the side airbag sensor LH to the con nector d Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wai...

Page 831: ...ive terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI...

Page 832: ...bly LH consists 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...

Page 833: ...n page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ignition switch to ACC or ON and wait at least for 20 seconds e Check the DTC See page DI 358 HINT Codes ot...

Page 834: ...Using a service wire connect SSL and ESL of the con nector on the side airbag sensor assembly side between the side airbag sensor assembly LH and the airbag sen sor assembly CHECK For the connector o...

Page 835: ...nnect VUPL and FSL of the connector on the side airbag sensor assembly side between the side air bag sensor assembly LH and the airbag sensor assembly CHECK For the connector on the airbag sensor asse...

Page 836: ...mbly LH and the airbag sensor assembly measure the resistance between body ground and each of SSL VUPL and FSL OK Resistance 1 M or Higher NG Repair or replace harness or connector be tween side airba...

Page 837: ...least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI 358 c Turn the ignition switch to LOCK and wa...

Page 838: ...onnec tor and connect the side airbag sensor RH to the con nector d Connect negative terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wai...

Page 839: ...ive terminal cable to the battery and wait at least for 2 seconds CHECK a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear the DTC stored in memory See step 5 on page DI...

Page 840: ...SCRIPTION The front airbag sensor RH circuit consists of the airbag sensor assembly and front airbag sensor RH For details of the function of each component see OPERATION on page RS 2 DTC B1156 B1157...

Page 841: ...ate 2001 SIENNA RM787U INSPECTION PROCEDURE 1 Prepare for inspection See step 1 on page DI 486 2 Check front airbag sensor RH circuit CHECK For the connector on the airbag sensor assembly side be twee...

Page 842: ...sor assembly side be tween the front airbag sensor RH and the airbag sensor as sembly measure the resistance between SR and body ground OK Resistance 1 M or Higher NG Go to step 9 OK 4 Check front air...

Page 843: ...CHECK a Turn ignition switch to ACC or ON and wait at least for 20 seconds b Clear DTC stored in memory See page DI 358 c Turn ignition switch to LOCK and wait at least for 20 se conds d Turn ignition...

Page 844: ...sensor connector RH CHECK For the connector on the front airbag sensor side measure the resistance between SR and SR OK Resistance 754 886 NG Replace front airbag sensor RH OK 7 Check relay harness P...

Page 845: ...or on the relay harness side between the front airbag sensor RH and the relay harness measure the resis tance between SR and SR OK Resistance Below 1 NG Repair or replace relay harness OK Repair or re...

Page 846: ...front airbag sensor RH and the relay harness measure the resis tance between body ground and each of SR and SR OK Resistance Below 1 M or Higher NG Repair or replace relay harness OK Repair or replac...

Page 847: ...ION Disconnect the relay harness connector on the airbag sensor assembly side CHECK For the connector on the relay harness side between the front airbag sensor RH and the relay harness measure the vol...

Page 848: ...he front airbag sensor LH circuit consists of the airbag sensor assembly and front airbag sensor LH For details of the function of each component see OPERATION on page RS 2 DTC B1158 B1159 16 is recor...

Page 849: ...ate 2001 SIENNA RM787U INSPECTION PROCEDURE 1 Prepare for inspection See step 1 on page DI 486 2 Check front airbag sensor LH circuit CHECK For the connector on the airbag sensor assembly side be twee...

Page 850: ...sor assembly side be tween the front airbag sensor LH and the airbag sensor as sembly measure the resistance between SL and body ground OK Resistance 1 M or Higher NG Go to step 7 OK 4 Check front air...

Page 851: ...a Turn the ignition switch to ACC or ON and wait at least for 20 seconds b Clear DTC stored in memory See page DI 358 c Turn the ignition switch to LOCK and wait at least for 20 seconds d Turn the ig...

Page 852: ...787U 6 Check front airbag sensor LH PREPARATION Disconnect the front airbag sensor connector LH CHECK For the connector on the front airbag sensor side measure the resistance between SL and SL OK Resi...

Page 853: ...TION Disconnect the front airbag sensor connector LH CHECK For the connector on the airbag sensor assembly side be tween the front airbag sensor LH and the airbag sensor as sembly measure the resistan...

Page 854: ...RATION Disconnect the front airbag sensor connector LH CHECK For the connector on the airbag sensor assembly side be tween the front airbag sensor LH and the airbag sensor as sembly measure the voltag...

Page 855: ...ncrease circuit DC DC converter functions to increase the voltage of the SRS to normal voltage The diagnosis system malfunction display for this circuit is different from other circuits that is when t...

Page 856: ...R B R W B B L W B B O GR ACC IG2 L W W W W E1 4 1V 3 4 4 3 3 ACC IG2 IG1 ST2 6 2 2 2 2 2 2 6 6 5 5 5 1 1 4 3 27 1N 1N 1N 1K 1K 1K 1B 1B 1K 2B 2L 2L 2D F8 F8 C5 AM1 AM1 AM2 CIG AM2 IGN ALT INP IG Left...

Page 857: ...ve the steering wheel pad See page SR 1 1 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...

Page 858: ...ignition switch to LOCK 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 preten...

Page 859: ...e SRS is normal the SRS warning light lights up for approx 6 seconds after the ignition switch is turned from the LOCK position to ACC or ON position and then turns off automatically If there is a mal...

Page 860: ...3 3 5 2 1 2J 2B C5 27 E1 W 21 A A 4 3 1V 1N IG EC Drive Side J B No 1 J14 Junction Connector J6 Junction Connector C9 SRS Warning Light J8 Junction Connector Left Cowl Side Pannel Rear Side of the Sur...

Page 861: ...See step 1 on page DI 486 2 Does SRS warning light turn off PREPARATION a Turn the ignition switch to LOCK b Disconnect negative terminal cable from the battery and wait at least for 90 seconds c Disc...

Page 862: ...ty HINT Fuse may be burnt out even if it appears to be OK during visual inspection If fuse is OK install it NG Go to step 5 OK 2 Prepare for inspection See step 1 on page DI 486 3 Check SRS warning li...

Page 863: ...4 Does SRS warning light come on PREPARATION a Disconnect negative terminal cable from the battery b Connect the airbag sensor assembly connector c Connect negative terminal cable to the battery and w...

Page 864: ...RESTRAINT SYSTEM DI 495 649 Author Date 2001 SIENNA RM787U 5 Is new SRS fuse burnt out again NO Using simulation method reproduce malfunc tion symptoms See page IN 21 YES Check harness between SRS fu...

Page 865: ...EM 650 Author Date 2001 SIENNA RM787U Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and CG of the DLC3 the airbag sensor assembly is set in the DTC output mode The DTCs are displa...

Page 866: ...ver Side J B No 1 DLC1 BR BR F F PB 18 IH2 11 E1 Tc A A 3 3 4 1V 1N J6 Junction Connector J14 Junction Connector Rear Side of the Surge Tank Left Coel Side Pannel EC IG DIAGNOSTICS SUPPLEMENTAL RESTRA...

Page 867: ...following troubleshooting 1 Does SRS warning light light up for approx 6 seconds PREPARATION Check operation of the SRS warning light after ignition switch is turned from LOCK position to ACC or ON po...

Page 868: ...negative terminal cable from the battery 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 illus...

Page 869: ...etween terminal Tc of airbag sensor assembly and body ground PREPARATION a Turn the ignition switch to LOCK b Disconnect negative terminal cable from the battery and wait at least for 90 seconds c Dis...

Page 870: ...sis 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 Accel...

Page 871: ...assembly Wire harness ON B0106 54 DI 392 Open in P squib circuit Front passenger airbag assembly squib Airbag sensor assembly Wire harness ON B0107 51 DI 395 Short in P squib circuit to ground Front...

Page 872: ...etensioner LH squib Airbag sensor assembly Wire harness Blink B0136 74 DI 444 Open in P T squib LH circuit Seat belt pretensioner LH squib Airbag sensor assembly Wire harness Blink B0137 71 DI 447 Sho...

Page 873: ...ource drops 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 When 2 or more cod...

Page 874: ...FF 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...

Page 875: ...bly 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 Side Airbag...

Page 876: ...RS warning light lights up even when the ignition switch is OFF a short in the SRS warning light circuit can be considered likely Proceed to SRS warning light circuit malfunction on page DI 490 2 DTC...

Page 877: ...odes have been output there will be a 4 0 second pause and they will all be repeated HINT In the event of a number of trouble codes indication will start from the smallest numbered code If a DTC is no...

Page 878: ...e terminal Tc remain grounded HINT When alternately grounding terminals Tc and AB release ground from one terminal and immediately ground the other ter minal within an interval of 0 2 seconds If DTCs...

Page 879: ...procedure as shown in the il lustration of the connectors on the next pages insert paper which has the same thickness as the male terminal between the terminal and the short spring CAUTION Never relea...

Page 880: ...ide 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 Pretens...

Page 881: ...ector Short Spring Short Spring Short Spring Before Release After Release Connector Connector Short Spring Short Spring Before Release Paper After Release Paper 4 5 Paper 2 1 3 6 Connector 7 15 Paper...

Page 882: ...the SRS warning light sometimes lights up after approx 6 seconds have elapsed SRS warning light is always lit up even when ignition switch is in the LOCK position SRS warning light circuit DI 490 With...

Page 883: ...Warning Light C5 5 IG2 Power Source C5 6 ACC Power Source C5 9 SR Front Airbag Sensor RH C5 10 P Squib Passenger C5 11 P Squib Passenger C5 12 SIL Diagnosis C5 13 D Squib Driver C5 14 D Squib Driver C...

Page 884: ...Switch LH C4 12 SSL Side Airbag Sensor LH C6 1 SFR Squib Side RH C6 2 SFR Squib Side RH C6 5 PR Squib Pretensioner RH C6 6 PR Squib Pretensioner RH C6 7 SSR Side Airbag Sensor RH C6 9 SSR Side Airbag...

Page 885: ...Lock and Unlock Switch Circuit CIRCUIT DESCRIPTION The back door courtesy switch goes ON when back door key cylinder is opened and goes OFF when the back door is closed WIRING DIAGRAM INSPECTION PROC...

Page 886: ...n theft deterrent ECU and back door courtesy switch See page IN 31 NG Repair or replace harness or connector OK Check and replace theft deterrent ECU 1 1 When there is a malfunction that prevents the...

Page 887: ...No 1 1G LG R 1S 7 1 R G 4 T3 T3 1 R Y R Y IG2 19 R Y R Y Junction Connector R Y R Y II4 IC2 II2 3 18 3 IG2 13 R G R G R G R G J B No 3 3B 3C 3 8 5 A A A J5 DIAGNOSTICS THEFT DETERRENT SYSTEM DI 557 71...

Page 888: ...doors are closed NG Check and repair open door warning light cir cuit OK 2 Check for open in harness and connector between theft deterrent ECU and door courtesy switch See page IN 31 NG Repair or repl...

Page 889: ...Door Key Lock and Unlock Switch RH Door Key Lock and Unlock Switch LH 8 1 DIAGNOSTICS THEFT DETERRENT SYSTEM DI 553 707 Author Date 2001 SIENNA RM787U Door Key Lock and Unlock Switch Circuit CIRCUIT D...

Page 890: ...d unlock switch is turned to the lock side unlock side and not turned OK Switch position Tester connection Specified condition Lock side 2 1 Continuity Unlock side 3 1 Continuity OFF No continuity NG...

Page 891: ...Door Unlock Detection Switch Front RH L B L B W B II2 W B A W B A W B L B J4 Junction Connector Y Y Y Y L L L L 3 4 1 w o Power slide door 2 w Power slide door 4 2 5 2 DIAGNOSTICS THEFT DETERRENT SYST...

Page 892: ...ob is oper ated to the lock side and unlock side OK Switch Condition Tester connection Specified condition Door unlock 1 4 Continuity Door lock No continuity NG Replace door unlock detection switch OK...

Page 893: ...F9 FL MAIN Battery B L 2B 3 2J 18 11 1 7 ALT 1 1 IG1 Driver Side J B No 1 R W 7 2 L W DOOR 3D R Driver Side J B No 1 3 W R 1B 2 W R 2 1 DIAGNOSTICS THEFT DETERRENT SYSTEM DI 535 689 Author Date 2001...

Page 894: ...CHECK Check continuity of DOME and DOOR fuses OK Continuity NG Check for short in all the harness and compo nents connected to the DOME and DOOR fuses See attached wiring diagram OK 2 Check voltage be...

Page 895: ...DI 537 691 Author Date 2001 SIENNA RM787U 3 Check for open in harness and connector between ECU and body ground See page IN 31 NG Repair or replace harness or connector OK Check and repair harness and...

Page 896: ...THEFT DETERRENT SYSTEM DI 559 713 Author Date 2001 SIENNA RM787U Engine Hood Courtesy Switch Circuit CIRCUIT DESCRIPTION The engine hood courtesy switch is built into the engine hood lock assembly and...

Page 897: ...r CHECK Check continuity between terminals 1 and 2 when engine hood lock is locked and unlocked OK Engine hood lock Tester connection Specified condition LOCK No continuity UNLOCK 1 2 Continuity NG Re...

Page 898: ...is activated it causes the Tr in the ECU to switch ON and OFF at intervals This switches the headlight control relay ON and OFF thus flashing the headlights See the wiring diagram below In this condi...

Page 899: ...the light control switch is operated proceed to troubleshooting on page BE 2 1 Check voltage between terminal HEAD of theft deterrent ECU connector and body ground PREPARATION Disconnect the theft det...

Page 900: ...ECU to switch ON and OFF in cycles This switches the horn relay ON and OFF thus the horns blow See the wiring diagram below In this condition if any of the following operations is done the Tr in the E...

Page 901: ...ot normal when the horn switch is operated check the horn switch 1 Check voltage between terminal HORN of theft deterrent ECU connector and body ground PREPARATION Disconnect the theft deterrent ECU c...

Page 902: ...Switch Circuit CIRCUIT DESCRIPTION When the ignition switch is turned to the ACC position battery positive voltage is applied to the terminal ACC of the ECU Also if the ignition switch is turned to th...

Page 903: ...hort in all the harness and compo nents connected to the CIG and ECU IG fuses See attached wiring diagram OK 2 Check voltage between terminal IG and ACC of theft deterrent ECU and body ground PREPARAT...

Page 904: ...TEM DI 533 687 Author Date 2001 SIENNA RM787U CIRCUIT INSPECTION Indicator Light Circuit CIRCUIT DESCRIPTION When the theft deterrent system is preparing to set this circuit lights up the indicator li...

Page 905: ...dicator light connector OK Indicator light comes on NG Replace combination meter OK 2 Check harness and connector between theft deterrent ECU and indicator light indicator light and body ground See pa...

Page 906: ...STICS THEFT DETERRENT SYSTEM DI 549 703 Author Date 2001 SIENNA RM787U Key Unlock Warning Switch Circuit CIRCUIT DESCRIPTION The key unlock warning switch goes ON when the ignition key is inserted in...

Page 907: ...removed OK Switch position Tester connection Specified condition ON Key inserted 1 2 Continuity OFF Key removed No continuity NG Replace key unlock warning switch OK 2 Check harness and connectors be...

Page 908: ...o switch ON and OFF at intervals This switches the taillight control relay ON and OFF thus flashing the taillights See the wiring diagram be low In this condition if any of the following operations is...

Page 909: ...the light control switch is operated proceed to troubleshooting on page BE 2 1 Check voltage between terminal TAIL of theft deterrent ECU connector and body ground PREPARATION Disconnect the theft det...

Page 910: ...e ECU close alternately causing the theft deterrent horn to blow See the wiring diagram below In this condition if any of the following operations is done the contact a in the ECU opens thus stopping...

Page 911: ...and disconnect the connector CHECK Measure voltage between terminal 1 of theft deterrent horn connector and body ground OK Voltage 10 14V NG Check and repair harness and connector be tween HORN fuse a...

Page 912: ...ERRENT SYSTEM 694 Author Date 2001 SIENNA RM787U 3 Check harness and connector between theft deterrent ECU and theft deterrent horn See page IN 31 NG Check and repair harness or connector OK Check and...

Page 913: ...lock control system When the key is inserted in the ignition key cylinder and turned to ACC or ON position However only when the system has never operated When the back door is opened with the key Sys...

Page 914: ...reak out box P DI 517 P DI 532 P IN 21 P DI 533 DI 559 Symptom occur 6 DI 516 DIAGNOSTICS THEFT DETERRENT SYSTEM 670 Author Date 2001 SIENNA RM787U THEFT DETERRENT SYSTEM HOW TO PROCEED WITH TROUBLESH...

Page 915: ...Unlock Waning Switch Driver Side J B No 1 DOOR Fuse ECU IG Fuse TAIL Relay Engine Room J B No 2 DOME Fuse HORN Fuse ST Relay HORN Relay HEAD Relay Theft Deterrent ECU Ignition Switch DI 528 DIAGNOSTIC...

Page 916: ...h Door Courtesy Switch Back Door Lock Assembly Door Unlock Detection Switch Back Door Courtesy Switch Back Door Key Lock and Unlock Switch Door Lock Assembly Door Unlock Detection Switch Door Courtesy...

Page 917: ...OF PASSIVE MODE Condition Any of the doors Including the engine hood and luggage compartment door is unlocked or opened without the key 1 The battery terminal is disconnected and reconnected The syst...

Page 918: ...light and sound to people around the vehicle Refer to the table for alarming method or time Horn Al i th d Security horn Alarming method Headlight Taillight Alarming time 60 seconds Alarming output Co...

Page 919: ...lock the locked doors using the wireless remote function Unlock the locked doors using the key Insert the key into the ignition key cylinder and turn the ignition key ON Any of the following condition...

Page 920: ...en in disarming condition the indicator light flash Due to the signal output form immobilizer system The indicator always flashes receiving the signal from the immobilizer system at any time in the ar...

Page 921: ...m will go to Armed state Allow 30 seconds to elapse with all the doors hood and luggage compart ment door closed Perform any of the following and the system will return to Disarmed state A Push the un...

Page 922: ...m any of the following and the system will return to Disarmed state A Push the unlock switch on the wireless remote Put the key in the lock on the driver s or the passenger door and turn it towards un...

Page 923: ...escribed above is met When the condition is not met the system judges theft occurs the mode transfers to alarming condition Indicator light output Condition Indicator light Disarming condition OFF Arm...

Page 924: ...to each condition In this case active mode continues till disarming condition Passive mode when transfer condition is met Active mode transfer condition Disarming condition Arming preparation conditio...

Page 925: ...door is closed and opened 3 to 5 times Driver s side knob for door lock is locked and unlocked The system starts force lock at once after 2 sec PASSIVE MODE ON Within 20 sec Within 30 sec HINT Initia...

Page 926: ...HELD TESTER a Hook up the break out box and hand held tester to the vehicle b Read the ECU input output values by following the prompts on the tester screen HINT Hand held tester has a Snapshot functi...

Page 927: ...switch circuit It is not canceled when the ignition key is turned to ACC or ON position It still operates when the back door is opened with the key When the system is set Ignition switch circuit Back...

Page 928: ...ened Below 1 DSWD E T3 4 T4 7 LG R W B Door courtesy switch OFF Driver s door Closed 1 M or higher DSWP E R G W B Door courtesy switch ON Passenger s door opened Below 1 DSWP E T3 5 T4 7 R G W B Door...

Page 929: ...or higher LSWR E L B W B Door unlock detection switch ON Rear door Below 1 LSWR E T3 16 T4 7 L B W B Door unlock detection switch OFF Rear door 1 M or higher B2 E T4 1 T4 7 L W W B Always 10 14 V IND...

Page 930: ...light goes on for about 3 seconds when the ignition switch is turned ON NG Proceed to troubleshooting for the ABS warn ing light circuit See page DI 250 OK 2 Is ABS DTC output Check ABS DTC on page DI...

Page 931: ...M INSPECTION PROCEDURE PREPARATION a Turn the ignition switch OFF b Using SST connect terminals Ts and E1 of DLC1 SST 09843 18020 c Start the engine 1 Check operation of tire pressure warning standard...

Page 932: ...ssure warning standardization switch when the switch is ON and OFF OK Switch position Condition ON pushed Continuity OFF released No continuity 1M or higher NG Replace the tire pressure warning standa...

Page 933: ...RE 1 Check tire pressure warning light goes on for about 3 seconds when the ignition switch is turned on OK Proceed to next circuit inspection shown in problem symptoms table See page DI 212 NG Troubl...

Page 934: ...s side and body ground OK Voltage 10 14 V OK Proceed to next circuit inspection shown in problem symptoms table See page DI 212 NG 4 Check for open circuit in harness and connector between tire pressu...

Page 935: ...and the tire was filled up air but the warning light does not go off Remains ON Does not Light Up Check Item ABS Warning Light Normal Malfunction Code Code Symptoms km miles Tire Pressure Warning Syst...

Page 936: ...tion Symptom Simulation P IN 21 Symptom does not occur Symptom occurs Circuit Inspection P DI 213 to DI 215 P DI 212 Identification of Problem Repair Confirmation Test End 1 2 3 4 5 6 7 Problem Sympto...

Page 937: ...ht Switch DLC1 Tire Pressure Warning Standardization Switch Front Speed Sensor Front Speed Sensor Rotor Front Speed Sensor Rotor Front Speed Sensor 1 ABS Actuator Assembly DIAGNOSTICS TIRE PRESSURE WA...

Page 938: ...re is used and tire chains are wound When using the tire with the air pressure extremely higher than the specified and the air pressure becomes acutely low due to burst during driving When the vehicle...

Page 939: ...ng standardization switch circuit See page DI 215 4 INSPECT TIRE PRESSURE WARNING STAN DARDIZATION SWITCH See page DI 215 5 INSPECT STOP LIGHT SWITCH See page DI 243 6 INSPECT ABS ECU See page DI 225...

Page 940: ...3 ABS actuator assembly and speed sensor 4 Ti i li ht i it DI 217 DI 213 Tire ressure warning system does not o erate Tire pressure warning light abnormal 4 Tire pressure warning light circuit 5 Tire...

Page 941: ...ssories switched OFF e All vacuum 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 mete...

Page 942: ...uled shorted or improperly gapped plugs Open or crossed high tension cords 6 Incorrect valve clearance 7 Leaky intake and exhaust valves 8 Leaky cylinders Low High Rough idle Fluctuating HC reading 1...

Page 943: ...ly charged battery to obtain engine speed of 250 rpm or more d Repeat steps a through c for each cylinder NOTICE This measurement must be done in as short a time as pos sible Compression pressure 1 50...

Page 944: ...or A C Compressor Housing Bracket No 1 Oil Pan x 15 Oil Pump Gasket Gasket Engine Wire Generator Drain Plug x 10 No 2 Oil Pan Oil Strainer Non reusable part N m kgf cm ft lbf Specified torque Precoate...

Page 945: ...sher Rear Oil Seal Retainer Cylinder Block Upper Main Bearing Upper Crankshaft Thrust Washer Crankshaft Lower Crankshaft Thrust Washer Lower Main Bearing Main Bearing Cap Seal Washer Non reusable part...

Page 946: ...STING BAR AND BRACKET ASSEMBLY a Disconnect the 2 wire clamps from the wire brackets b Remove the 3 nuts the generator adjusting bar and bracket assembly 5 REMOVE OIL PRESSURE SWITCH See page LU 1 6 R...

Page 947: ...10 12 REMOVE OIL STRAINER See page LU 10 13 REMOVE NO 1 OIL PAN See page LU 10 14 REMOVE OIL PUMP See page LU 10 15 REMOVE OIL FILTER See page LU 3 16 REMOVE OIL FILTER UNION Using a 12 mm hexagon wr...

Page 948: ...cting rod thickness 20 80 20 85 mm 0 8189 0 8209 in 22 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly...

Page 949: ...ings If necessary grind or replace the crankshaft HINT If replacing a bearing replace it with one having the same num ber as marked on the connecting rod There are 4 sizes of stan dard bearings marked...

Page 950: ...0 0760 0 0780 in 25 REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE a Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several passes in the se quence shown b Uniforml...

Page 951: ...across each journal i Install the 4 main bearing caps See page EM 108 Torque 12 pointed head bolts 1st 22 N m 225 kgf cm 16 ft lbf 2nd Turn extra 90 Hexagon head bolts 27 N m 275 kgf cm 20 ft lbf NOT...

Page 952: ...PLE Cylinder block 06 Crankshaft 08 Use bearing 5 EM 96 ENGINE MECHANICAL CYLINDER BLOCK 1039 Author Date 2001 SIENNA RM787U HINT If using a bearing replace it with one having the same number If the n...

Page 953: ...nkshaft B Use Bearing Total number Number Mark 0 5 6 11 12 17 18 23 24 28 1 2 3 4 5 V08070 No 2 and No 3 journal standard bearings selection chart Crankshaft number mark Cylinder block number mark EXA...

Page 954: ...4012 60 992 2 4012 60 991 2 4012 60 990 2 4012 60 989 2 4011 60 988 2 4011 Standard bearing center wall thickness TMC made 1 2 3 4 5 6 7 2 486 2 489 0 0979 0 0980 2 489 2 492 0 0980 0 0981 2 492 2 495...

Page 955: ...g expander remove the 2 compression rings b Remove the 2 side rails and oil ring by hand HINT Arrange the piston rings in the correct order only 29 DISCONNECT CONNECTING ROD FROM PISTON a Using a smal...

Page 956: ...high temperatures the cylinder liner sticks out beyond the cylinder block so always wash the cylinder block at a temperature of 45 C 113 F or less 3 INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS...

Page 957: ...449 3 4453 in Maximum diameter 87 52 mm 3 4457 in If the diameter 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 ream...

Page 958: ...ngles to the piston pin center line 23 2 mm 0 913 in from the piston head Piston diameter 87 406 87 416 mm 3 4412 3 4416 in b Measure the cylinder bore diameter in the thrust direc tions See step 5 c...

Page 959: ...nd LH banks The RH piston is marked with R the LH piston with L 11 INSPECT PISTON RING GROOVE CLEARANCE Using a feeler gauge measure the clearance between new pis ton right and the wall of the ring gr...

Page 960: ...r twist Maximum twist 0 15 mm 0 0059 in per 100 mm 3 94 in If twist is greater than maximum replace the connecting rod as sembly 15 INSPECT PISTON PIN OIL CLEARANCE a Using a caliper gauge measure the...

Page 961: ...ng SST 09222 30010 d Using a pin hole grinder hone the bushing to obtain the standard specified clearance see step 15 above be tween the bushing and piston pin e Check the piston pin fit at normal roo...

Page 962: ...e diameter is not as specified check the oil clearance See disassembly in cylinder block If necessary replace the crankshaft b Check each main journal and crank pin for taper and out of round as shown...

Page 963: ...ylinder 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 Apply MP grease to a new oi...

Page 964: ...new parts 1 ASSEMBLE PISTON AND CONNECTING ROD a 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...

Page 965: ...er Side Rail Front Mark LH Piston No 2 Compression Expander No 1 Compression Front Mark or ENGINE MECHANICAL CYLINDER BLOCK EM 109 1052 Author Date 2001 SIENNA RM787U 2 INSTALL PISTON RINGS a Install...

Page 966: ...and No 4 cylinder block journal positions with the main bearing cap Install the 19 0 mm 0 748 in bearings in the No 2 and No 3 positions Upper bearings have an oil groove and oil holes lower bearings...

Page 967: ...the threads and under the main bearing cap bolts for the 12 pointed head d Temporarily install the 8 main bearing cap bolts to the in side positions e Insert the main bearing cap with your hand until...

Page 968: ...n bearing cap bolts does not meet the torque specification replace the main bearing cap bolt c Mark the front of the main bearing cap bolts with paint d Retighten the main bearing cap bolts by 90 in t...

Page 969: ...ont mark of the piston facing forward HINT The shape of the piston varies for the RH and LH banks The RH piston is marked with R the LH piston with L 12 PLACE CONNECTING ROD CAP ON CONNECTING ROD a Ma...

Page 970: ...ial and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block Using a razor blade and gasket scraper remove all the oil packing FIPG material from the gask...

Page 971: ...o the seal plate as shown in the il lustration Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 3 5 mm 0 12 0 20 in opening Parts must be assembled within 3 minut...

Page 972: ...n stall cap c Install the water inlet housing with the 8 bolts and 2 nuts Uniformly tighten the bolts and nuts in several passes in the sequence shown Torque 8 N m 80 kgf cm 69 in lbf d Install the en...

Page 973: ...p Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector 20 205 15 RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver E...

Page 974: ...e Mounting Bracket PS Pump Drive Belt PS Vane Pump 43 440 32 64 650 47 32 320 23 MAF Meter Connector EVAP Hose Air Cleaner Cap Gasket Front Exhaust Pipe Gasket 33 330 24 Gasket 62 630 46 Stay Non reus...

Page 975: ...Cable Ground Strap Air Intake Chamber Assembly Gasket Water Bypass Hose Vacuum Hose Heater Hose Intake Manifold Assembly Injector Connector N m kgf cm ft lbf ECT Sender Gauge Connector ECT Sensor Con...

Page 976: ...ler Pulley 43 440 32 125 1 300 35 88 900 65 RH Camshaft Timing Pulley LH Camshaft Timing Pulley Timing Belt Tensioner 27 280 20 Timing Belt Guide No 2 Generator Bracket 215 2 200 159 125 1 300 94 Dust...

Page 977: ...pstick Guide N m kgf cm ft lbf Specified torque Non reusable part Gasket Engine Wire Engine Wire 49 500 36 Bushing Camshaft Position Sensor LH Exhaust Manifold Stay x 6 Gasket O Ring O Ring LH Exhaust...

Page 978: ...er Head Camshaft Bearing cap Camshaft Oil Seal RH Cylinder Head RH Cylinder Head Gasket LH Cylinder Head Gasket 18 185 13 x8 16 160 12 See Page EM 60 1st 54 550 40 2nd Turn 90 N m kgf cm ft lbf Specif...

Page 979: ...Using SST compress the valve spring and remove the 2 keepers SST 09202 70020 09202 00010 b Remove the spring retainer c Remove the valve spring d Remove the valve e Using needle nose pliers remove the...

Page 980: ...A05275 EM 42 ENGINE MECHANICAL CYLINDER HEAD 985 Author Date 2001 SIENNA RM787U 4 REMOVE OIL CONTROL VALVE FILTER Remove the plug gasket and valve filter...

Page 981: ...der block surface 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 remov...

Page 982: ...measure the surfaces contacting the cylinder block and the manifolds for warpage Maximum warpage 0 10 mm 0 0039 in If warpage is greater than maximum replace the cylinder head 7 INSPECT FOR CRACKS Usi...

Page 983: ...er measurement from the guide bushing guide bushing inside diameter measure ment Standard oil clearance Intake 0 025 0 060 mm 0 0010 0 0024 in Exhaust 0 030 0 065 mm 0 0012 0 0026 in Maximum oil clear...

Page 984: ...INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b Check the valve seating position Apply a light coat of prussian blue...

Page 985: ...g a steel square measure the deviation of the valve spring Maximum deviation 2 0 mm 0 079 in If the deviation is greater than maximum replace the valve spring b Using vernier calipers measure the free...

Page 986: ...864 mm 1 6836 1 6876 in Minimum cam lobe height Intake 42 78 mm 1 6842 in Exhaust 42 61 mm 1 6776 in If the cam lobe height is less than minimum replace the cam shaft 15 INSPECT CAMSHAFT JOURNALS Usin...

Page 987: ...tely remove the Plastigage h Remove the camshafts 18 INSPECT CAMSHAFT THRUST CLEARANCE a Install the camshafts See page EM 60 b Using a dial indicator measure the thrust clearance while moving the cam...

Page 988: ...e air pressure VVT i will turn to the advance angle side without applying force by hand Also under the condition that the pressure can be hardly applied because of the air leakage from the port there...

Page 989: ...ance 0 024 0 050 mm 0 0009 0 0020 in Maximum oil clearance 0 07 mm 0 0028 in If the oil clearance is greater than maximum replace the lifter If necessary replace the cylinder head 23 INSPECT AIR INTAK...

Page 990: ...ontacting the cylinder head for warpage Maximum warpage 0 50 mm 0 0196 in If warpage is greater than maximum replace the manifold 26 INSPECT 12 POINTED HEAD CYLINDER HEAD BOLTS Using vernier calipers...

Page 991: ...2 progressive steps steps c and e If any bolt is broken or deformed replace it a Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts b Install the plate was...

Page 992: ...ing an 8 mm hexagon wrench install the cylinder head bolt on each cylinder head then repeat for the other side as shown Torque 18 5 N m 185 kgf cm 13 ft lbf 4 ASSEMBLE EXHAUST CAMSHAFTS a Mount the he...

Page 993: ...arance of the camshaft is small the camshaft must be held level while it is being installed If the camshaft is not level the portion of the cylinder head re ceiving the shaft thrust may crack or be da...

Page 994: ...several passes in the sequence shown Torque 16 N m 160 kgf cm 12 ft lbf b Install the intake camshaft 1 Apply new engine oil to the thrust portion and jour nal of the camshaft 2 Align the timing mark...

Page 995: ...er head re ceiving the shaft thrust may crack or be damaged causing the camshaft to seize or break To avoid this the following steps should be carried out a Install the exhaust camshaft 1 Apply new en...

Page 996: ...camshaft 1 Apply new engine oil to the thrust portion and jour nal of the camshaft 2 Align the timing marks 1 dot mark of the camshaft drive and driven gears 3 Place the intake camshaft on the cylind...

Page 997: ...ug grooves Seal packing Part No 08826 00080 or equivalent c Install the 2 semi circular plugs to the cylinder heads 9 INSTALL CYLINDER HEAD COVERS a Apply seal packing to the cylinder heads as shown i...

Page 998: ...Torque 8 0 N m 80 kgf cm 69 in lbf e Install the dipstick 13 INSTALL LH EXHAUST MANIFOLD a Install a new gasket and the exhaust manifold with the 6 nuts Uniformly tighten the nuts in several passes To...

Page 999: ...xcess gasket After installing the gasket press down on it so that the adhesive firmly sticks to the timing belt cover b Install the timing belt cover with the 6 bolts Torque 8 5 N m 85 kgf cm 74 in lb...

Page 1000: ...LY a Using an 8 mm hexagon wrench install a new gasket and the air intake chamber assembly with the 2 bolts and 2 nuts Uniformly tighten the bolts and nuts in several passes Torque 43 N m 440 kgf cm 3...

Page 1001: ...nnect the accelerator cable 29 INSTALL AIR CLEANER CAP HOSE WITH RESONA TOR 30 INSTALL V BANK COVER a Using a 5 mm hexagon wrench install the V bank cover with the 3 cap nuts b Press down the V bank c...

Page 1002: ...of the spark plug tube Adhesive Part No 08833 00070 THREE BOND 1324 or equivalent b Using a press press in a new spark plug tube until there is 42 4 43 4 mm 1 669 1 709 in protruding from the camshaft...

Page 1003: ...fail ure b Install the valve c Install the spring seat d Install the valve spring e Install the spring retainer f Using SST compress the valve spring and place the 2 keepers around the valve stem SST...

Page 1004: ...A05276 ENGINE MECHANICAL CYLINDER HEAD EM 59 1002 Author Date 2001 SIENNA RM787U 6 INSTALL CYLINDER HEAD REAR COVER Install the rear cover and gasket with the 6 bolts Torque 10 N m 100 kgf cm 7 ft lbf...

Page 1005: ...V bank cover fastener counterclockwise c Remove the V bank cover 9 REMOVE AIR CLEANER HOSE WITH RESONATOR 10 REMOVE AIR INTAKE CHAMBER ASSEMBLY a Disconnect the accelerator cable b Disconnect the thr...

Page 1006: ...le body bracket s Using an 8 mm hexagon wrench remove the 2 bolts 2 nuts the air intake chamber assembly and gasket 11 REMOVE INTAKE MANIFOLD ASSEMBLY a Disconnect the 6 injector connectors b Disconne...

Page 1007: ...5 REMOVE TIMING BELT See page EM 16 16 REMOVE CAMSHAFT TIMING PULLEYS See page EM 16 17 REMOVE NO 2 IDLER PULLEY See page EM 16 18 REMOVE NO 3 TIMING BELT COVER a Disconnect the 3 engine wire clamps f...

Page 1008: ...ET PIPE FROM LH CYL INDER HEAD AND WATER INLET a Remove the bolt and disconnect the inlet pipe from the water inlet b Remove the O ring from the inlet pipe 26 REMOVE PS PUMP BRACKET Remove the 3 bolts...

Page 1009: ...thrust clearance of the camshaft is small the camshaft must be held level while it is being removed If the camshaft is not kept level the portion of the cylinder head receiving the shaft thrust may c...

Page 1010: ...AD NOTICE Since the thrust clearance of the camshaft is small the camshaft must be held level while it is being removed If the camshaft is not kept level the portion of the cylinder head receiving the...

Page 1011: ...ce shown 2 Remove the 5 bearing caps oil seal and exhaust camshaft HINT Arrange the camshafts in the correct order Arrange the bearing caps in the correct order 33 DISASSEMBLE EXHAUST CAMSHAFTS a Moun...

Page 1012: ...r head 12 pointed head bolts on each cylinder head in several passes in the sequence shown then repeat for the other side as shown Remove the 16 cylinder head bolts and plate washers NOTICE Head warpa...

Page 1013: ...g SST and a 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 Select a new guide bushing STD or...

Page 1014: ...remove or install the camshaft timing gear VVT i beside changing VVT i or the camshaft a Mount the hexagon wrench head portion of the camshaft in a vise NOTICE Be careful not to damage the camshaft b...

Page 1015: ...ise the prescribed torque cannot be obtained f Using a 46 mm socket wrench install and torque a new lock nut by turning it counterclockwise Torque 150 N m 1 530 kgf cm 110 ft lbf NOTICE Must change th...

Page 1016: ...001 SIENNA RM787U d Using SST and a hammer tap in a new gasket until its sur face is flush with the upper edge of the cylinder head cov er SST 09608 03071 e Apply a light coat of MP grease to the gask...

Page 1017: ...Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector 20 205 15 RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver Hood 26 265 19 N m kgf cm ft lbf Specified...

Page 1018: ...y Tray Accelerator Cable Cruise Control Actuator Connector Cruise Control Actuator LH Fender Apron Seal A C Compressor Connector Drain Plug EVAP Hose MAF Meter Connector A T Oil Cooler Hose Non reusab...

Page 1019: ...ting Stay Gasket Gasket Gasket Front Exhaust Pipe Stay 62 630 46 43 440 32 33 330 24 LH Fender Liner RH Fender Liner LH Rear Lower Brace RH Rear Lower Brace RH Front Lower Brace LH Front Lower Brace 1...

Page 1020: ...rber N m kgf cm ft lbf Specified torque PS Pump Drive Belt PS Oil Pressure Switch Connector Heated Oxygen Sensor Bank 1 Sensor 1 Connector 43 440 32 48 490 35 Front Suspension Member PS Vane Pump Gree...

Page 1021: ...Transaxle Throttle Cable Precoated part 83 850 61 x 8 Rear Plate Front Spacer x 6 Drive Plate 41 420 30 Flywheel Housing Under Cover Exhaust Pipe Support Stay LH Exhaust Manifold Stay 20 200 14 37 380...

Page 1022: ...h the transaxle to the engine b Install the ground strap and 8 bolts Torque A bolt 48 N m 490 kgf cm 35 ft lbf B bolt 37 N m 380 kgf cm 48 ft lbf Other bolt 66 N m 670 kgf cm 48 ft lbf c Install the L...

Page 1023: ...r with the 4 bolts Torque 64 N m 650 kgf cm 47 ft lbf 8 INSTALL FRONT ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts Torque 64 N m 650 kgf cm 47 ft lbf 9 INSTALL FRONT SUSPE...

Page 1024: ...1 sensor 1 connector clamp e Connect the PS oil pressure switch connector 11 INSTALL ENGINE TRANSAXLE AND FRONT SUSPENSION MEMBER ASSEMBLY IN VEHICLE a Attach the engine sling device to the engine han...

Page 1025: ...EMBLY See page SR 20 21 INSTALL DRIVE SHAFTS See page SA 23 22 CONNECT STABILIZER BAR LINK See page SA 42 23 INSTALL ENGINE FENDER APRON SEALS 24 INSTALL FRONT EXHAUST PIPE a Temporarily install 3 new...

Page 1026: ...brake booster vacuum hose to air intake chamber g Connect the engine coolant reservoir hose to water out let h Connect the heater hose to intake manifold i Connect the heater hose to water inlet hous...

Page 1027: ...5 ft lbf f Install the 2 wiper arm head caps 37 INSTALL HOOD 38 INSTALL V BANK COVER 39 FILL ENGINE WITH OIL 40 FILL WITH ENGINE COOLANT 41 BLEED POWER STEERING SYSTEM See page SR 4 42 START ENGINE AN...

Page 1028: ...CRUISE CONTROL ACTUATOR 10 REMOVE RADIATOR See page CO 17 11 DISCONNECT A T OIL COOLER PIPE a Disconnect the A T oil cooler hose from the A T oil cooler pipe b Remove the bolt and disconnect the A T...

Page 1029: ...nect the A C compressor from the engine 15 DISCONNECT A T SHIFT CONTROL CABLE FROM TRANSAXLE 16 REMOVE FRONT EXHAUST PIPE a Remove the 2 bolts holding the support stay to the sup port bracket b Remove...

Page 1030: ...SLING DEVICE TO ENGINE HANGERS a Install the No 2 engine hanger in the correct direction Part No No 2 engine hanger 12282 20020 Bolt 91642 80825 Torque 19 5 N m 200 kgf cm 14 ft lbf b Attach the sling...

Page 1031: ...of all wiring hoses and cables 30 DISCONNECT PS VANE PUMP FROM ENGINE a Disconnect the PS oil pressure switch connector b Disconnect the heated oxygen sensor bank 1 sensor 1 connector clamp c Remove...

Page 1032: ...bolts and mounting insulator 33 REMOVE REAR ENGINE MOUNTING INSULATOR FROM ENGINE Remove the 4 bolts the mounting insulator and bracket assem bly 34 REMOVE STARTER See page ST 5 35 DISCONNECT ENGINE W...

Page 1033: ...SIENNA RM787U 37 REMOVE TRANSAXLE a Remove the bolt nut and LH exhaust manifold stay b Remove the 8 bolts and ground strap c Remove the transaxle together with the torque converter clutch from the eng...

Page 1034: ...ont Exhaust Pipe Stay 21 210 15 Heat Insulator Gasket 56 570 41 Heat Insulator Heated Oxygen Sensor Bank 1 Sensor 2 Tailpipe Ring 19 190 14 Heat Insulator Bracket Ring Gasket Ring Gasket 43 440 32 Spr...

Page 1035: ...ll vacuum lines properly connected f SFI system wiring connectors fully plugged g Ignition timing check correctly h Transmission in neutral position 2 CONNECT TOYOTA HAND HELD TESTER OR OBDII SCAN TOO...

Page 1036: ...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 4...

Page 1037: ...TDC idle Transmission in neutral position HINT The timing mark moves in a range between 7 and 24 8 DISCONNECT TIMING LIGHT FROM ENGINE 9 DISCONNECT TOYOTA HAND HELD TESTER OR OBDII SCAN TOOL 10 REINST...

Page 1038: ...Cap Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector 20 205 15 RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver...

Page 1039: ...Control Rod RH Engine Mounting Stay No 2 RH Engine Mounting Bracket Ground Strap PS Pump Drive Belt Engine Coolant Reservoir Hose 64 650 47 32 320 23 N m kgf cm ft lbf Specified torque DLC1 EM 14 ENG...

Page 1040: ...r RH Camshaft Timing Pulley No 2 Idler Pulley Dust Boot 215 2 200 159 43 440 32 27 280 20 Timing Belt Tensioner N m kgf cm ft lbf Specified torque Non reusable part 28 290 21 No 1 Timing Belt Cover 12...

Page 1041: ...n b If the belt teeth are cracked or damaged check to see if either camshaft is locked c If there is noticeable wear or cracks on the belt face check to see if there are nicks on the side of the idler...

Page 1042: ...l on the push rod side the tensioner is all right If leakage is found replace the tensioner b Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn t move I...

Page 1043: ...or equivalent a Using a 10 mm hexagon wrench install the plate washer and idler pulley with the pivot bolt Torque 34 N m 350 kgf cm 25 ft lbf b Check that the pulley bracket moves smoothly 3 INSTALL...

Page 1044: ...ll the crankshaft pulley bolt to the crankshaft Turn the crankshaft and align the timing marks of the crankshaft timing pulley and oil pump body b Camshaft Timing Pulley Positions Using SST turn the c...

Page 1045: ...s slowly press in the push rod using 981 9 807 N 100 1 000 kgf 200 2 205 lbf of pressure b Align the holes of the push rod and housing pass a 1 27 mm hexagon wrench through the holes to keep the set t...

Page 1046: ...terial Thoroughly clean all components to remove all the loose material Remove the backing paper from a new gasket and install the gasket evenly to the part of the timing belt cover shaded black in th...

Page 1047: ...ve of the pulley and slide on the pulley b Using SST install the pulley bolt SST 09213 54015 91651 60855 09330 00021 Torque 215 N m 2 200 kgf cm 159 ft lbf 16 INSTALL NO 2 GENERATOR BRACKET Install th...

Page 1048: ...NECT ENGINE COOLANT RESERVOIR HOSE FROM WATER OUTLET 7 DISCONNECT GROUND STRAP CONNECTORS 8 DISCONNECT DLC1 FROM NO 2 RH ENGINE MOUNT ING BRACKET 9 REMOVE RH ENGINE MOUNTING STAY ENGINE MOVING CONTROL...

Page 1049: ...he 5 bolts and timing belt cover 15 REMOVE RH ENGINE MOUNTING BRACKET Remove the 2 bolts nut and mounting bracket 16 SET NO 1 CYLINDER TO TDC COMPRESSION a Temporarily install the crankshaft pulley bo...

Page 1050: ...s on the timing belt to match the timing marks of the timing pulleys and place a new front mark on the timing belt 18 REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts and remove them the te...

Page 1051: ...LEY Using a 10 mm hexagon wrench remove the bolt idler pulley and plate washer 23 REMOVE CRANKSHAFT TIMING PULLEY a Remove the bolt and timing belt plate b Using SST remove the crankshaft timing pulle...

Page 1052: ...CT RADIATOR HOSE FROM WATER OUT LET 8 REMOVE CYLINDER HEAD COVERS See page EM 33 9 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align its groove with the timing mark 0 of the...

Page 1053: ...indicated in the illustration Measure the valve clearance See procedure step a c Turn the crankshaft a further 2 3 of a revolution 240 and check only the valves indicated in the illustration Measure...

Page 1054: ...being stuck insert it gently from the intake side at a slight angle Using a small screwdriver and magnetic finger remove the adjusting shim b Determine the replacement adjusting shim size according to...

Page 1055: ...nd re move SST B SST 09248 55040 09248 05410 09248 05420 d Recheck the valve clearance 12 REINSTALL CYLINDER HEAD COVERS See page EM 60 13 CONNECT RADIATOR HOSE TO WATER OUTLET 14 REINSTALL IGNITION C...

Page 1056: ...asured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a new No 12 shim New shim thickness mm in Thickness Thickness Shim No Shim No ters imprinted on the face HINT New shims...

Page 1057: ...easured clearance is 0 450 mm 0 0177 in Replace the 2 800 mm 0 1102 in shim with a new No 10 shim New shim thickness mm in Thickness Thickness Shim No Shim No ters imprinted on the face HINT New shims...

Page 1058: ...sed 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 Warm Up Three Way Catalytic...

Page 1059: ...itching Valve Connector Charcoal Protector EVAP Line Hose Vent Line Hose 6 N m kgf cm ft lbf Specified torque 19 5 195 14 19 5 195 14 EMISSION CONTROL EVAPORATIVE EMISSION EVAP CONTROL SYSTEM EC 5 106...

Page 1060: ...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 por...

Page 1061: ...o TOYOTA 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 from the VSV terminals for the EVAP 3 Connect...

Page 1062: ...ternal pressure of the fuel tank can be hold for 1 minute c Check the connected portions of each hose and pipe d Check the installed parts on the fuel tank if there is no abnormality replace the fuel...

Page 1063: ...r connector c Disconnect the fuel hose from the vapor pressure sensor d Disconnect the purge line hose EVAP line hose and air inlet line hose from the charcoal canister e Disconnect the vent line hose...

Page 1064: ...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 i...

Page 1065: ...CV 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 Petro...

Page 1066: ...ort Purge Line EVAP Line Vent Line Air Drain Hose VSV for Pressure Switching Valve VSV for Canister Closed Valve CCV Air Cleaner A F Sensor Bank 1 Sensor 1 A F Sensor Bank 2 Sensor 1 WU TWC for Bank 2...

Page 1067: ...ister EVAP Service Port PCV Valve Air Inlet Line WU TWC for Bank2 WU TWC for Bank1 VSV for Canister Closed Valve CCV VSV for Vacuum Switching Valve EC 2 EMISSION CONTROL PARTS LAYOUT AND SCHEMATIC DRA...

Page 1068: ...56 571 43 Gasket Heated Oxygen Sensor Bank1 Sensor2 Ring N m kgf cm ft lbf Specified torque Non reusable part 43 440 32 Spring 20 200 14 Protector EMISSION CONTROL THREE WAY CATALYTIC CONVERTER TWC S...

Page 1069: ...MBLY a Check the connections for looseness or damage b Check the clamps for weakness cracks or damage 2 INSPECT TWC Check for dents or damage If any part of the protector is damaged or dented to the e...

Page 1070: ...WU TWC for Bank 1 Gasket Gasket 43 440 32 Spring 62 630 46 Front Exhaust Pipe WU TWC for Bank 1 Gasket 33 330 24 Spring 43 440 32 62 630 46 Stay EC 12 EMISSION CONTROL WARM UP THREE WAY CATALYTIC CON...

Page 1071: ...or Bank 2 Gasket w WU TWC 62 630 46 Gasket LH Exhaust Manifold x 6 LH Exhaust Manifold Heat Insulator LH Exhaust Manifold Stay A F Sensor 44 450 33 49 500 63 EMISSION CONTROL WARM UP THREE WAY CATALYT...

Page 1072: ...WU TWC SYSTEM ON VEHICLE INSPECTION 1 INSPECT EXHAUST PIPE ASSEMBLY a Check the connections for looseness or damage b Check the clamps for weakness cracks or damage 2 INSPECT WU TWC Check for dents or...

Page 1073: ...sonator Vacuum Hose Accelerator Cable Air Intake Chamber Stay V Bank Cover IAC Valve Connector Throttle Position Sensor Connector Specified torque Non reusable part N m kgf cm ft lbf Vacuum Hose No 1...

Page 1074: ...rottle Body 6 9 70 61 in lbf N m kgf cm ft lbf Non reusable part Specified torque No 1 Intake Air Control Valve Gasket 6 9 70 61 in lbf No 1 No 2 Throttle Body SFI ACOUSTIC CONTROL INDUCTION SYSTEM AC...

Page 1075: ...Gasket Actuator Vacuum Hose Ground Strap Ground Cable Specified torque Non reusable part 14 5 145 10 N m kgf cm ft lbf No 2 Brake Booster Vacuum Hose SF 60 SFI ACOUSTIC CONTROL INDUCTION SYSTEM ACIS...

Page 1076: ...the vacuum in a check that the actuator rod does not return If the operation is not as specified replace the intake air control valve 2 INSPECT VACUUM TANK LOCATION The LH side member under the batter...

Page 1077: ...nstall the No 2 intake air control valve 1 Install a new gasket to the air intake chamber 2 Apply a light coat of engine oil to the rubber por tions 3 Apply seal packing to the positions of the intake...

Page 1078: ...ACIS ON VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE a Using a 3 way connector connect vacuum gauge to the actuator hose b Start the engine c While the engine is idling check that the vacuum g...

Page 1079: ...TROL VALVE See pages SF 36 and SF 40 2 DISCONNECT ACTUATOR VACUUM HOSE 3 DISCONNECT BRAKE BOOSTER VACUUM HOSE 4 REMOVE INTAKE AIR CONTROL VALVE a Remove the 4 nuts and disconnect the ground strap and...

Page 1080: ...SPECTION INSPECT HEATER RESISTANCE OF A F SENSORS Bank 1 Sensor 1 Bank 2 Sensor 1 a Disconnect the A F sensor connector b Using an ohmmeter measure the resistance between ter minals B and HT Resistanc...

Page 1081: ...NTINUITY a Using an ohmmeter check that there is no continuity be tween terminals 1 and 2 If there is continuity replace the relay b Check that there is continuity between terminals 3 and 5 If there i...

Page 1082: ...UIT OPENING RELAY 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 termi...

Page 1083: ...ontrol Valve LH Camshaft Timing Oil Control Valve RH Camshaft Timing Oil Control Valve Connector LH Camshaft Timing Oil Control Valve Connector N m kgf cm ft lbf Specified torque 7 5 80 66 in lbf SFI...

Page 1084: ...es in direction SFI CAMSHAFTTIMING OIL CONTROL VALVE SF 55 1130 Author Date 2001 SIENNA RM787U INSPECTION INSPECT CAMSHAFT OIL CONTROL VALVE OPERATION Connect the positive lead from the battery to ter...

Page 1085: ...SF0SP 08 SF 56 SFI CAMSHAFTTIMING OIL CONTROL VALVE 1131 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 54...

Page 1086: ...E INSPECTION INSPECT OIL CONTROL VALVE RESISTANCE a Remove the V bank cover b Disconnect the oil control valve connector c Using an ohmmeter measure the resistance between the terminals Resistance 6 9...

Page 1087: ...tion please refer to the following items Press down the V bank cover fastener c Remove the V bank cover 2 REMOVE CAMSHAFT TIMING OIL CONTROL VALVES a Disconnect the 2 camshaft oil control valve connec...

Page 1088: ...5 ECM ECM Connector No 2 Instrument Panel Finish Lower Panel Cowl Side Trim Front Door Inside Sculf Plate SFI ENGINE CONTROL MODULE ECM SF 83 1158 Author Date 2001 SIENNA RM787U ENGINE CONTROL MODULE...

Page 1089: ...SF0JS 01 SF 84 SFI ENGINE CONTROL MODULE ECM 1159 Author Date 2001 SIENNA RM787U INSPECTION 1 REMOVE ECM 2 INSPECT ECM See page DI 19 3 REINSTALL ECM...

Page 1090: ...1 DRAIN ENGINE COOLANT 2 REMOVE ECT SENSOR a Disconnect the ECT sensor connector b Using a 19 mm deep socket wrench remove the ECT sensor and gasket 3 INSPECT ECT SENSOR Using an ohmmeter measure the...

Page 1091: ...RELAY 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...

Page 1092: ...nect 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 4 INSPECT FUEL CUT OFF PRM a Incr...

Page 1093: ...e Connector X8 Tube Joint Clip Fuel Tube Fuel Tank Vent Tube Set Plate Fuel Pump Assembly Gasket Rubber Cushion Fuel Pressure Regulator No 2 Fuel Suction Support O Ring 4 0 40 35 in lbf SF 18 SFI FUEL...

Page 1094: ...SF0IM 01 SF 20 SFI FUEL PRESSURE REGULATOR 1095 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 19...

Page 1095: ...or Date 2001 SIENNA RM787U REMOVAL 1 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK See page SF 1 1 2 REMOVE NO 2 FUEL SUCTION SUPPORT See page SF 13 3 REMOVE FUEL PRESSURE REGULATOR a Pull out the pressure...

Page 1096: ...g Fuel Tank Band Fuel Inlet Pipe Protector Fuel Tank Protector N m kgf cm ft lbf Specified Torque Non reusable part Fuel Tank Main Tube Fuel Inlet Hose Fuel Inlet Pipe Gasket Fuel Inlet Pipe Shield Fu...

Page 1097: ...lines for cracks or leakage and all connec tions for deformation b Check the fuel tank vapor vent system hoses and connec tions for looseness sharp bends or damage c Check the fuel tank for deformatio...

Page 1098: ...30 SFI FUEL TANK AND LINE 1105 Author Date 2001 SIENNA RM787U FUEL TANK AND LINE PRECAUTION Always use new gaskets when replacing the fuel tank or component parts Apply the proper torque to all parts...

Page 1099: ...Vent Tube Set Plat Fuel Pump Assembly Gasket Vapor Pressure Sensor Joint Clip Fuel Sunction Plate Sender Gauge O Ring Cap Fuel Filter No 2 Fuel Filter Cushion No 1 Fuel Suction Support O Ring Fuel Pr...

Page 1100: ...2 fuel suction support b Remove the rubber cushion 3 REMOVE FUEL PRESSURE REGULATOR Pull out the fuel pressure regulator from the fuel filter 4 REMOVE FUEL PUMP FILTER NOTICE Do not damage the fuel su...

Page 1101: ...MP 1089 Author Date 2001 SIENNA RM787U 6 REMOVE FUEL FILTER AND FUEL PUMP a Remove the fuel filter and pump from the fuel suction plate b Disconnect the fuel pump connector from the fuel pump 7 DISCON...

Page 1102: ...SF0IJ 01 SFI FUEL PUMP SF 17 1092 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 1 1...

Page 1103: ...e no TOYOTA hand held tester connect the positive and negative leads from the battery to the fuel pump connector See step 7 f Check that there is pressure in the fuel inlet hose from the fuel pipe HIN...

Page 1104: ...gasoline h Reconnect the TOYOTA hand held tester to the DLC3 See step 1 i Reconnect the negative terminal cable to the battery j Measure the fuel pressure Fuel pressure 301 347 kPa 3 1 3 5 kgf cm2 44...

Page 1105: ...talling the clamp check that the clamp is fixed by pulling up to the clamp t Reconnect the negative terminal cable to the battery u Check for fuel leaks 3 DISCONNECT FUEL PUMP SENDER GAUGE CON NECTOR...

Page 1106: ...SFI FUEL PUMP SF 9 1084 Author Date 2001 SIENNA RM787U If operation is not as specified replace the fuel pump or lead wire 6 RECONNECT FUEL PUMP SENDER GAUGE CON NECTOR...

Page 1107: ...ump connector to the fuel pump b Install the fuel filter and fuel pump to the fuel suction plate 3 INSTALL NO 1 FUEL SUCTION SUPPORT a Install the No 2 fuel filter cushion to the fuel filter b Install...

Page 1108: ...fuel pump filter to the fuel pump b Install the new clip c Install the rubber cushion 6 INSTALL NO 2 FUEL SUCTION SUPPORT Install the No 2 fuel suction support to the No 1 fuel suction sup port 7 INST...

Page 1109: ...lation please refer to the following items Check for fuel leakage 2 DISCONNECT FUEL TUBE a Wash away the mud dust and the likes on the fuel suction plate with water b Pull off the tube joint clip form...

Page 1110: ...BLY FROM FUEL TANK a Remove the 8 bolts and fuel tank vent tube set plate Torque 4 0 N m 40 kgf cm 35 in lbf b Pull out the fuel pump assembly NOTICE Do not damage the fuel pump filter Be careful that...

Page 1111: ...nce 11 16 at 20 C 68 F If the resistance is not as specified replace the sensor Torque 44 N m 440 kgf cm 31 ft lbf c Reconnect the oxygen sensor connector 2 INSPECT HEATER RESISTANCE OF HEATED OXYGEN...

Page 1112: ...ue 29 300 22 Air Cleaner Hose w Resonator Vacuum Hose Accelerator Cable IAC Valve Gasket Throttle Body Throttle Body Bracket Throttle Position Sensor Connector IAC Valve Connector V Bank Cover Vacuum...

Page 1113: ...at the IAC valve is halfly opened b Connect the IAC valve connector to the IAC valve c Turn the ignition switch ON d Check that the IAC valve moves in 0 5 seconds by order of fully close fully open an...

Page 1114: ...SF0J8 01 SFI IDLE AIR CONTROL IAC VALVE SF 51 1126 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 49...

Page 1115: ...he DLC1 SST 09843 18020 2 INSPECT AIR ASSIST SYSTEM a Initial conditions Engine at normal operating temperature Idle speed checked correctly Transmission in neutral position A C switch OFF b Using SST...

Page 1116: ...4 Author Date 2001 SIENNA RM787U REMOVAL 1 REMOVE THROTTLE BODY See page SF 40 2 REMOVE IAC VALVE Remove the 4 screws bracket IAC valve and gasket HINT At the time of installation please refer to the...

Page 1117: ...iper Arm Head Cap Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Lo...

Page 1118: ...Ground Cable Ground Strap VSV Connector for No 2 ACIS Purge Hose Air Assist Hose and Pipe 19 5 200 14 Retainer Injector Connector Delivery Pipe 10 100 7 Spacer O Ring Grommet Injector Insulator O Ring...

Page 1119: ...SST 09268 41047 CAUTION Preform connecting operations of the fuel tube connector quick type after observing the precautions See page SF 1 c Install the grommet and O Ring to the injector d Connect SS...

Page 1120: ...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...

Page 1121: ...counterclock wise push it to the delivery pipes Install the 6 injectors e Position the injector connector outward f Place the 4 spacers in position on the intake manifold g Apply a light coat of spind...

Page 1122: ...nnecting operations of the fuel tube connector quick type after observing the precautions b Surely install the fuel hose clamp to the fuel filter with click sound c After installing the clamp check th...

Page 1123: ...hat there is normal operating noise in proportion to engine speed 2 If you have no sound scope you can check the in jector operating vibration with your finger If no sound or unusual sound is heard ch...

Page 1124: ...ASSIST HOSES AND PIPE a Disconnect the air assist pipe from the bracket on the No 1 fuel pipe b Remove the air assist hoses from the intake manifold 7 DISCONNECT NO 1 FUEL PIPE a Remove the fuel hose...

Page 1125: ...emoving the delivery pipes Pay attention to put any hung load on the injector to and from the side direction a Remove the 5 bolts and delivery pipes together with the 6 injectors and fuel pipe b Remov...

Page 1126: ...Head Cap Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver 20...

Page 1127: ...43 440 32 Ground Strap DLC1 Gasket 15 150 11 Grand Strap Connector Gasket 39 400 29 V Bank Cover Accelerator Cable Air Cleaner Hose w Resonator Purge Hose Vacuum Hose Fuel Hose Clamp Heater Hose Intak...

Page 1128: ...ensor connector b Using SST remove the knock sensor SST 09817 1601 1 6 INSPECT KNOCK SENSORS Using an ohmmeter check that there is no continuity between the terminal and body If there is continuity re...

Page 1129: ...SF0IV 03 B12670 Mass Air Flow MAF Meter Mass Air Flow MAF Meter Connector O ring SFI MASS AIR FLOW MAF METER SF 33 1108 Author Date 2001 SIENNA RM787U MASS AIR FLOW MAF METER COMPONENTS...

Page 1130: ...HA E2 2 21 2 69 k 20 C 68 F THA E2 0 49 0 67 k 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 ignitio...

Page 1131: ...SF0IY 01 SF 36 SFI MASS AIR FLOW MAF METER 1111 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 34...

Page 1132: ...4 SFI MASS AIR FLOW MAF METER 1109 Author Date 2001 SIENNA RM787U REMOVAL REMOVE MAF METER a Disconnect the MAF meter connector b Remove the 2 screws MAF meter and O ring HINT At the time of installat...

Page 1133: ...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 i...

Page 1134: ...I 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 o...

Page 1135: ...ing a new O ring on the injector take care not to damage it in any way 3 Coat a new O ring with spindle oil or gasoline be fore installing never use engine gear or brake oil e Install the injector to...

Page 1136: ...ctions is tight apply little amount of new engine oil on the tip of the pipe 5 After having finished the connection check if the pipe and the connector are securely connected by pulling them 6 Check i...

Page 1137: ...ual for further details 5 If you have no TOYOTA hand held tester connect the positive and negative leads from the bat tery to the fuel pump connector See page SF 6 6 Check that there are no leaks from...

Page 1138: ...eaner Hose w Resonator Vacuum Hose Accelerator Cable Throttle Body Bracket V Bank Cover IAC Valve Connector Throttle Position Sensor Connector Specified torque Non reusable part N m kgf cm ft lbf Vacu...

Page 1139: ...O Ring No 2 Throttle Body No 1 Throttle Body 6 9 70 61 in lbf Gasket IAC Valve N m kgf cm ft lbf Non reusable part Specified torque No 1 Intake Air Control Valve Gasket 6 9 70 61 in lbf Bracket SFI T...

Page 1140: ...rottle opener using a MITYVAC Hand Held Vacuum Pump Standard Must have no clearance NOTICE As the throttle stop screw is precisely adjusted so do not adjust it b Under the condition of 1 check visuall...

Page 1141: ...on the No 1 lever goes off from the throttle stop screw causing the adjust ment failure 3 Turn it back from the position where it touches the lever to the screw loosing direction Standard Turn it back...

Page 1142: ...SF0J3 01 SF 46 SFI THROTTLE BODY 1121 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SF 40...

Page 1143: ...s Resistance Fully closed VTA E2 0 2 6 3 k Fully open VTA E2 2 0 10 2 k VC E2 2 5 5 9 k d Reconnect the sensor connector 3 INSPECT THROTTLE OPENER a Allow the engine to warm up to normal operating tem...

Page 1144: ...l mount c Loosen the 3 hose clamps and remove the air cleaner hose with the resonator 4 DISCONNECT ACCELERATOR CABLE AND THROTTLE CABLE 5 REMOVE THROTTLE BODY a Remove the bolt holding the throttle bo...

Page 1145: ...1116 Author Date 2001 SIENNA RM787U k Remove the 3 nuts throttle body and gasket HINT At the time of installation please refer to the following items Place a new gasket on the air intake chamber Torq...

Page 1146: ...einstall a new throttle position sensor 1 Check that the throttle valve is fully close 2 Insert the sensor to the throttle body with it turned counterclockwise by 30 to 60 against the fully close valv...

Page 1147: ...SIENNA RM787U b Remove the 6 screws No 1 throttle body No 2 throttle body and 2 gaskets from the No 1 intake air control valve c Place 2 new gaskets and 2 new O rings as shown in the illustration d R...

Page 1148: ...SV Connector for EVAP VSV Connector for No 2 ACIS Emission Control Valve Set VSV Connector for No 1 ACIS No 1 SFI VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM ACIS SF 69 1144 Author Date 2001 SIENNA RM78...

Page 1149: ...Hose VSV for No 2 ACIS VSV Connector for EVAP VSV Connector for No 2 ACIS Emission Control Valve Set VSV Connector for No 1 ACIS No 2 SF 70 SFI VSV FOR ACOUSTIC CONTROL INDUCTION SYSTEM ACIS 1145 Auth...

Page 1150: ...is continuity between each terminals Resistance 33 39 at 20 C 68 F If there is no continuity replace the VSV 4 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each t...

Page 1151: ...nister Closed Valve CCV VSV Connector for Canister Closed Valve CCV Air Hose O Ring Non reusable part SF 72 SFI VSV FOR CANISTER CLOSED VALVE CCV 1147 Author Date 2001 SIENNA RM787U VSV FOR CANISTER C...

Page 1152: ...en the terminals Resistance At 20 C 68 F 25 30 At 120 C 248 F 33 42 If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each...

Page 1153: ...P VSV Connector for EVAP VSV Connector for No 2 ACIS VSV Connector for No 1 ACIS VSV for No 2 ACIS Emission Control Valve Set SFI VSV FOR EVAPORATIVE EMISSION EVAP SF 67 1142 Author Date 2001 SIENNA R...

Page 1154: ...een the terminals Resistance 27 33 at 20 C 68 F If there is no continuity replace the VSV 4 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the bod...

Page 1155: ...83 VSV for Pressure Switching Valve Vacuum Hose VSV Connector for Pressure Switching Valve SF 74 SFI VSV FOR PRESSURE SWITCHING VALVE 1149 Author Date 2001 SIENNA RM787U VSV FOR PRESSURE SWITCHING VAL...

Page 1156: ...n the terminals Resistance At 20 C 68 F 37 44 At 120 C 248 F 51 62 If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each t...

Page 1157: ...tank b Turn the ignition 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 Reconn...

Page 1158: ...that there is continuity between terminals 3 and 4 If there is no continuity replace the relay c Inspect the No 1 cooling fan relay operation 1 Apply battery voltage across terminals 1 and 2 2 Using a...

Page 1159: ...ntinuity between terminals 3 and 5 If there is no continuity replace the relay d Install the No 2 cooling fan relay 3 INSPECT NO 3 COOLING FAN RELAY a Remove the No 3 cooling fan relay Marking FAN NO...

Page 1160: ...K ENGINE COOLANT QUALITY a Remove the radiator cap from the water outlet CAUTION To avoid the danger of being burned do not remove the radiator cap while the engine and radiator are still hot as fluid...

Page 1161: ...lbf LH engine drain plug on union 13 N m 130 kgf cm 9 ft lbf 2 FILL ENGINE COOLANT a Slowly fill the system with coolant Use a good brand of ethylene glycol base engine coolant and mix it according t...

Page 1162: ...n Shroud Fan Motor No 1 Electric Cooling Fan Connector Relay Block CANADA for Daytime Running Light System No 1 Electric Cooling Fan Non reusable part COOLING ELECTRIC COOLING FAN CO 21 1181 Author Da...

Page 1163: ...No 2 Fan Clip Fan Shroud Fan Motor No 2 Electric Cooling Fan Connector No 2 Electric Cooling Fan Non reusable part Upper Radiator Hose CO 22 COOLING ELECTRIC COOLING FAN 1182 Author Date 2001 SIENNA...

Page 1164: ...d fan NOTICE When removing the clip and fan do not apply too much force to the motor shaft And do not scratch the motor shaft HINT At the time assembly please refer to the following itemes Install a n...

Page 1165: ...CO08E 01 CO 26 COOLING ELECTRIC COOLING FAN 1186 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page CO 23...

Page 1166: ...r a separated connector or severed wire between the cooling fan relay and ECT switch c Disconnect the No 1 ECT switch connector d Check that the cooling fan rotates If not check the fuses engine main...

Page 1167: ...ly and check the reading on the ammeter Standard amperage ID mark S1 8 5 11 5 A at 20 C 68 F ID mark T1 14 0 20 0 A at 20 C 68 F f Reconnect the cooling fan connector 4 INSPECT NO 2 COOLING FAN a Star...

Page 1168: ...CO08D 01 COOLING ELECTRIC COOLING FAN CO 25 1185 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page CO 24...

Page 1169: ...nning light sys tem from the battery hold down clamp b Disconnect the cooling fan connector c Remove the 2 bolts and cooling fan Torque 5 0 N m 50 kgf cm 44 in lbf 2 REMOVE NO 2 COOLING FAN a Drain en...

Page 1170: ...tinuity replace the switch b Using an ohmmeter check that there is continuity be tween the switch terminals when the coolant temperature is below 88 C 190 F If there is no continuity replace the switc...

Page 1171: ...e tween terminals 3 and 5 If there is no continuity replace the relay b Check that there is continuity between terminals 2 and 4 If there is no continuity replace the relay c Check that there is no co...

Page 1172: ...e No 1 Electric Cooling Fan Connector Lower Radiator Support Drain Plug Relay Block CANADA for Daytime Running Light System Lower Radiator Hose A T Oil Cooler Hose Upper Radiator Support O Ring Non re...

Page 1173: ...CO088 01 CO 18 COOLING RADIATOR 1178 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page CO 17...

Page 1174: ...DIATOR ON VEHICLE CLEANING Using water or a steam cleaner remove any mud or dirt from the radiator core NOTICE If using a high pressure type cleaner be careful not to deform the fins of the radiator c...

Page 1175: ...seconds or more NOTICE Push the pump at a constant speed If air is not coming from the vacuum valve replace the radiator cap b Pump the tester and measure the relief valve opening pressure Pump speed...

Page 1176: ...tric cooling fan connector No 2 electric cooling fan connector Upper radiator hose from radiator Lower radiator hose from water inlet pipe 2 oil cooler hoses from oil cooler pipes c Remove the 2 bolts...

Page 1177: ...Specified torque ECT Switch Connector Engine Wire Protector Water Inlet Water Inlet Pipe O Ring Air Cleaner Cap Assembly Thermostat 8 0 80 69 in lbf 19 5 200 14 Gasket CO 10 COOLING THERMOSTAT 1170 A...

Page 1178: ...heat the water b Check the valve opening temperature Valve opening temperature 80 84 C 176 183 F If the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valv...

Page 1179: ...ibed position 2 INSTALL WATER INLET Install the water inlet with the 3 nuts Torque 8 0 N m 80 kgf cm 69 in lbf 3 INSTALL WATER INLET PIPE a Install a new O ring to the water inlet pipe b Apply soapy w...

Page 1180: ...AIR CLEANER HOSE 3 DISCONNECT ECT SWITCH CONNECTORS 4 DISCONNECT ENGINE WIRE PROTECTOR FROM WATER INLET AND RH CYLINDER HEAD Remove the 2 nuts and disconnect the engine wire protector from the water i...

Page 1181: ...Head Cap Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver 20...

Page 1182: ...tor Drive Belt RH Engine Mounting Stay PS Pump Drive Belt Engine Coolant Reservoir Hose Ground Strap RH Fender Apron Seal No 2 RH Engine Mounting Bracket DLC1 32 320 23 64 650 47 CO 4 COOLING WATER PU...

Page 1183: ...otector RH Camshaft Timing Pulley No 2 Idler Pulley Dust Boot Non reusable part For use with SST No 1 Timing Belt Cover LH Camshaft Timing Pulley N m kgf cm ft lbf Specified torque Timing Belt Tension...

Page 1184: ...ble part No 3 Timing Belt Cover Gasket Collar Bushing Water Pump Gasket Engine Wire 8 5 65 74 in lbf x 6 8 0 82 71 in lbf N m kgf cm ft lbf Specified torque CO 6 COOLING WATER PUMP 1166 Author Date 20...

Page 1185: ...N 1 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...

Page 1186: ...N m 82 kgf cm 71 in lbf NOTICE Do not get oil on the gasket 2 INSTALL NO 3 TIMING BELT COVER See page EM 60 3 INSTALL NO 2 IDLER PULLEY See page EM 22 4 INSTALL CAMSHAFT TIMING PULLEYS See page EM 22...

Page 1187: ...LANT 2 REMOVE OUTER FR COWL TOP PANEL ASSEMBLY See page EM 76 3 REMOVE TIMING BELT See page EM 16 4 REMOVE CAMSHAFT TIMING PULLEYS See page EM 16 5 REMOVE NO 2 IDLER PULLEY See page EM 16 6 REMOVE NO...

Page 1188: ...choice for your vehicle for good fuel economy and good starting in cold weath er 2 CHECK ENGINE OIL LEVEL After warm up the engine and then 5 minutes after the engine stop oil level should be between...

Page 1189: ...STALL OIL PRESSURE SWITCH a Remove the oil pressure gauge 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 S...

Page 1190: ...loves Wash your skin thor oughly with soap and water or use water less hand cleaner to remove any used engine oil Do not use gasoline thinners or solvents In order to preserve the environment used oil...

Page 1191: ...gasket Torque 45 N m 460 kgf cm 33 ft lbf b Fill with fresh engine oil Capacity Drain and refill w Oilfilter change w o Oilfilter change 4 7 liters 5 0 US qts 4 1 lmp qts 4 5 liters 4 8 US qts 4 0 lmp...

Page 1192: ...Head Cap Cowl Panel Hole Cover Hood to Cowl Top Seal Window Washer Hose Outer FR Cowl Top Panel Assembly Clip x 8 Wiper Motor Connector RH Cowl Top Ventilator Louver LH Cowl Top Ventilator Louver 20...

Page 1193: ...Strap Bracket Gasket Stay N m kgf cm ft lbf Specified torque PS PumpDriveBelt Adjusting Strut Gasket Gasket Non reusable part DLC1 A C Compressor Generator Drive Belt Adjusting Bar Bracket Generator...

Page 1194: ...lley Crankshaft Timing Pulley Dust Boot Timing Belt Plate Plate Washer 215 2 200 159 43 440 32 27 280 20 Timing Belt Tensioner N m kgf cm ft lbf Specified torque Non reusable part 28 290 21 No 1 Timin...

Page 1195: ...Wire Oil Strainer No 2 Oil Pan x 10 x 6 x 9 O Ring No 1 Oil Pan Gasket Drain Plug 8 5 85 74 in lbf 8 0 80 69 in lbf 10 mm Head 8 0 80 69 in lbf 12 mm Head 19 5 200 14 10 mm Head 8 0 80 69 in lbf 12 m...

Page 1196: ...Specified torque Non reusable part x 10 49 1 500 36 Crankshaft Front Oil Seal Relief Valve Spring Plug Oil Pump Body Driven Rotor Drive Rotor Oil Pump Body Cover LUBRICATION OIL PUMP LU 9 1199 Author...

Page 1197: ...2 LUBRICATION OIL PUMP 1202 Author Date 2001 SIENNA RM787U DISASSEMBLY 1 REMOVE RELIEF VALVE Remove the plug spring and relief valve 2 REMOVE DRIVE AND DRIVEN ROTORS Remove the 10 screws pump body cov...

Page 1198: ...andard side clearance 0 030 0 090 mm 0 0012 0 0035 in Maximum side clearance 0 15 mm 0 0059 in If the side clearance is greater than maximum replace the ro tors as a set If necessary replace the oil p...

Page 1199: ...ces and sealing grooves Thoroughly clean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces b Apply seal packing to the oil pump as shown in the il...

Page 1200: ...gasket scraper remove all the old packing FIPG material from the gasket sur faces and sealing grooves Thoroughly clean all components to remove all the loose material Using a non residue solvent clea...

Page 1201: ...lean all components to remove all the loose material Using a non residue solvent clean both sealing surfaces NOTICE Do not use a solvent which will affect the painted surfaces b Apply seal packing to...

Page 1202: ...ing bolts Torque 43 1 N m 440 kgf cm 32 ft lbf c Tighten the nut Torque 43 1 N m 440 kgf cm 32 ft lbf 10 INSTALL A C COMPRESSOR See page EM 82 11 INSTALL GENERATOR See page CH 2 12 INSTALL RH FENDER A...

Page 1203: ...VE AND DRIVEN ROTORS a Place the drive and driven rotors into pump body with the marks facing the pump body cover side b Install the pump body cover with the 10 screws 2 INSTALL RELIEF VALVE Insert th...

Page 1204: ...EAL 5 REMOVE FRONT EXHAUST PIPE See page EM 76 6 REMOVE GENERATOR FROM ENGINE See page CH 7 7 REMOVE A C COMPRESSOR FROM ENGINE See page EM 76 8 REMOVE PS PUMP DRIVE BELT AND ADJUSTING STRUT a Loosen...

Page 1205: ...IL STRAINER Remove the bolt 2 nuts oil strainer and gasket 15 REMOVE NO 1 OIL PAN a Remove the 2 bolts and No 1 exhaust pipe support brack et b Remove the 17 bolts and 2 nuts c Using a screwdriver rem...

Page 1206: ...oil seal 2 Using SST and a hammer tap in a new oil seal until its surface is flush with the oil pump body edge SST 09223 00010 3 Apply MP grease to the oil seal lip b If the oil pump is installed to...

Page 1207: ...9 in lbf V Bank Cover Camshaft Position Sensor Bank1 O Ring O Ring Camshaft Position Sensor Bank2 Camshaft Position Sensor Connector 8 0 80 69 in lbf Non reusable part Air Cleaner Cap IG 6 IGNITION CA...

Page 1208: ...ectors b Remove the bolt and camshaft position sensor Remove the 2 camshaft position sensors c Remove the O rings from the camshaft position sensors 4 REINSTALL NEW CAMSHAFT POSITION SENSORS a Install...

Page 1209: ...n Sensor Connector Crankshaft Position Sensor RH Fender Apron Seal N m kgf cm ft lbf Specified torque 8 0 80 69 in lbf IG 8 IGNITION CRANKSHAFT POSITION SENSOR 1217 Author Date 2001 SIENNA RM787U CRAN...

Page 1210: ...ANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove the bolt and crankshaft position sensor 3 REINSTALL NEW CRANKSHAFT POSITION SENSOR a Install a new crankshaft po...

Page 1211: ...B12840 V Bank Cover Ignition Coil w Igniter Ignition Coil Connector 8 0 80 69 in lbf N m kgf cm ft lbf Specified torque IG 4 IGNITION IGNITION COIL 1213 Author Date 2001 SIENNA RM787U IGNITION COIL CO...

Page 1212: ...the 6 ignition coil connectors b Remove the bolt and pull out the ignition coil Remove the 6 ignition coils 3 REINSTALL NEW IGNITION COILS a Connect a new ignition coil to the spark plug and attach t...

Page 1213: ...en try another CHANGE IT TO NORMAL IGNITION COIL WITH IGNITER AND PERFORM SPARK TEST AGAIN Replace crankshaft position sensor ECM OK IGNITER IGNITION IGNITION SYSTEM IG 1 1210 Author Date 2001 SIENNA...

Page 1214: ...on provides fairly accurate results Simple Method Quickly race the engine to 4 000 rpm 5 times Remove the spark plug See step c Visually check the spark plug If the electrode is dry OK If the electrod...

Page 1215: ...INSPECT IGNITION COILS WITH IGNITERS See step 1 4 INSPECT CAMSHAFT POSITION SENSORS a Remove the V bank cover b Remove the air cleaner hose w resonator c Disconnect the sensor connectors d Using an oh...

Page 1216: ...Starter Wire Starter Hold Down Clamp Battery Insulator Battery Battery Tray A T Shift Control Cable Clamp A T Shift Control Cable Engine Wire Relay Block Cruise Control Actuator Connector ST 2 STARTIN...

Page 1217: ...r Bearing Stop Collar Pinion Gear Compression Spring Spring Retainer Steel Ball Return Spring Front Bearing Armature O Ring Field Frame Field Coil End Cover Brush Holder Rear Bearing Dust Protector No...

Page 1218: ...t Plunger Gasket End Cover O Ring Packing Terminal Insulator Wave Washer Terminal Bolt Terminal 30 Kit Part Contact Plate Terminal Insulator N m kgf cm ft lbf Non reusable part Specified torque 17 170...

Page 1219: ...the armature HINT At the time of assembly please refer to the following items Align the protrusion of the field frame with the groove of the magnetic switch d Remove the O ring from the field frame HI...

Page 1220: ...ing from the field frame HINT At the time of assembly please refer to the following items Use a new O ring c Using a screwdriver hold the spring back and disconnect the brush from the brush holder Dis...

Page 1221: ...surface is dirty or burnt correct it with sandpaper No 400 or on a lathe 4 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial gauge measure the circle runout Maximum c...

Page 1222: ...is no continuity between the field coil end and field frame If there is continuity repair or replace the field frame 9 INSPECT BRUSH LENGTH Using a vernier caliper measure the brush length Standard le...

Page 1223: ...amage If damaged replace the gear or clutch assembly If damaged also check the drive plate ring gear for wear or damage 13 INSPECT CLUTCH Hold the starter clutch and rotate the pinion gear countercloc...

Page 1224: ...29 Author Date 2001 SIENNA RM787U 4 Using a screwdriver pry out the snap ring 5 Remove these parts Stop collar Pinion gear Compression spring 6 Push down the starter housing and remove the spring reta...

Page 1225: ...rass bar 3 Push down the starter housing and install these parts Spring retainer Compression spring Pinion gear Stop collar 4 Push down the pinion gear 5 Using snap ring pliers install a new snap ring...

Page 1226: ...elt or the bearing sticks replace the bearing 16 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing SST 09286 4601 1 b Using a press press in a new bearing 17 INSPECT FRONT BEARING Turn...

Page 1227: ...the bearing installation direction SST 09820 00030 19 INSPECT MAGNETIC SWITCH PULL IN COIL OPEN CIRCUIT Using an ohmmeter check that there is continuity between ter minals 50 and C If there is no con...

Page 1228: ...ST01F 01 ST 20 STARTING STARTER 1238 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page ST 5...

Page 1229: ...ER 1236 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page ST 6 HINT Use high temperature grease to lubricate the bearings springs steel ball and gear...

Page 1230: ...nect the actuator connector and clamp b Remove the 3 bolts and disconnect the actuator with the bracket 3 REMOVE STARTER a Disconnect the A T shift control cable b Disconnect the engine wire c Disconn...

Page 1231: ...ace the contact plate 3 REMOVE TERMINAL KIT PARTS a Using SST loosen the terminal nuts SST 09810 38140 b Terminal C Remove the terminal nut wave washer terminal insulator outside O ring terminal bolt...

Page 1232: ...ect direction b Terminal C Install these new parts 1 Terminal insulator inside 2 Contact plate 3 Terminal bolt 4 O ring 5 Terminal insulator outside 6 Wave washer 7 Terminal nut NOTICE Be careful to i...

Page 1233: ...n the nuts to the specified torque SST 09810 38140 Torque 17 N m 170 kgf cm 12 ft lbf NOTICE If the nut is over tightened it may cause cracks on the in side of the insulator 6 CLEAN CONTACT SURFACES O...

Page 1234: ...s shown 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 pi...

Page 1235: ...over and starter relay 2 INSPECT STARTER RELAY 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 i...

Page 1236: ...G SYSTEM ST 1 1219 Author Date 2001 SIENNA RM787U STARTING SYSTEM ON VEHICLE INSPECTION NOTICE Before changing the starter check the following items again Connector connection Accessory installation e...

Page 1237: ...CIFIC GRAVITY Check the specific gravity of each cell Standard specific gravity 1 25 1 29 at 20 C 68 F If the specific gravity is less than specification charge the bat tery 3 Maintenance Free Battery...

Page 1238: ...s been found replace the drive belt HINT Cracks on the rib side of a drive belt are considered acceptable If the drive belt has chunks missing from the ribs it should be replaced b Using a belt tensio...

Page 1239: ...ester is not available connect a voltmeter and amme ter to the charging circuit as follows Disconnect the wire from terminal B of the genera tor and connect it to the negative tester probe of the amme...

Page 1240: ...at 2 000 rpm turn on the high beam headlights and place the heater blower switch at HI b Check the reading on the ammeter Standard amperage 30 A or more If the ammeter reading is less than the standar...

Page 1241: ...SYSTEM PRECAUTION Check that the battery cables are connected to the correct terminals Disconnect the battery cables when the battery is given a quick charge Do not perform tests with a high voltage i...

Page 1242: ...ame Stator Front Bearing Bearing Cover Rear Bearing Bearing Cover Plate Terminal Rear End Cover Brush Holder Cover Brush Holder Voltage Regulator Rectifier Holder Rubber insulator x 4 Terminal Insulat...

Page 1243: ...OR a Remove the brush holder cover from the brush holder b Remove the 5 screws brush holder and voltage regulator 3 REMOVE RECTIFIER HOLDER a Remove the 4 screws and rectifier holder b Remove the 4 ru...

Page 1244: ...ation NOTICE 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 nu...

Page 1245: ...otor If there is continuity replace the rotor 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored If rough or scored replace the rotor b Using a vernier caliper measure the slip r...

Page 1246: ...nal and the other to each rectifier terminal b Reverse the polarity of the tester probes and repeat step a c Check that one shows continuity and the other shows no continuity If continuity is not as s...

Page 1247: ...ring SST 09950 60010 09951 00500 d Install the bearing retainer with the 4 screws Torque 3 0 N m 31 kgf cm 27 in lbf 11 INSPECT REAR BEARING Check that the bearing is not rough or worn 12 IF NECESSARY...

Page 1248: ...78 SST P00074 SST CHARGING GENERATOR CH 13 1252 Author Date 2001 SIENNA RM787U d Using SST and a press press in a new bearing SST 09820 00030 e Using SST push in the bearing cover outside SST 09285 76...

Page 1249: ...CH01Z 01 CHARGING GENERATOR CH 17 1256 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page CH 7...

Page 1250: ...AME a 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 cord clip with the 4 nuts Torque Nut A 4 5 N m 46 kgf cm 40...

Page 1251: ...sert SST B into SST C and attach the pulley nut to SST C f To torque the pulley nut turn SST A in the direction shown in the illustration Torque 110 5 N m 1 125 kgf cm 81 ft lbf g Remove the generator...

Page 1252: ...h holder on the recti fier end frame NOTICE Be careful of the holder installation direction b Install the 5 screws Torque 2 0 N m 20 kgf cm 18 in lbf c Place the brush holder cover on the brush holder...

Page 1253: ...olt adjusting lock bolt and adjusting bolt and remove the drive belt Torque Pivot bolt 56 N m 570 kgf cm 41 ft lbf Lock bolt 18 N m 180 kgf cm 13 ft lbf 2 REMOVE GENERATOR a Disconnect the generator c...

Page 1254: ...VALVE BODY See page AX 6 3 REMOVE SOLENOID WIRE a Remove the bolt and solenoid wire b Remove the O ring 4 INSTALL SOLENOID WIRE a Install a new O ring to the solenoid wire b Coat the O ring with ATF...

Page 1255: ...utch C2 One W ay Clutch No 2 F2 Forward Clutch C1 One W ay Clutch No 1 F1 Intermediate Shaft Rear Planetary Gear Input Shaft Shift lever position P N R D L 2 F0 Gear position C1 C2 F2 B1 B2 B3 Reverse...

Page 1256: ...RANSAXLE AUTOMATIC TRANSAXLE SYSTEM AX 1 1257 Author Date 2001 SIENNA RM787U AUTOMATIC TRANSAXLE SYSTEM PRECAUTION If the vehicle is equipped with a mobile communication system refer to the precaution...

Page 1257: ...bly Wiper Motor Connector Hood to Cowl Top Seal RH Cowl Top Ventilator Louver Window Washer Hose N m kgf cm ft lbf Specified torque x11 Clip Hood 26 265 19 20 205 15 LH Cowl Top Ventilator Louver AX 2...

Page 1258: ...nt Lower Brace PS Pipe Battery 181 1 850 134 49 500 36 294 3 000 217 44 450 32 15 150 11 10 100 7 36 370 27 181 1 850 134 66 670 48 36 370 27 32 330 24 N m kgf cm ft lbf Specified torque 80 820 59 19...

Page 1259: ...Connector Bracket Torque Converter Clutch Stay x 6 48 490 35 56 570 41 33 330 24 62 630 46 20 200 15 Solenoid Connector 41 420 30 66 670 48 Heated oxygen Sensor Gasket Gasket Non reusable part 8 0 80...

Page 1260: ...e be tween the installed surface and the front surface of the trans axle housing Correct distance More than 13 7 mm 0 539 in 2 TRANSAXLE INSTALLATION Installation is in the reverse order of removal Se...

Page 1261: ...e 15 N m 150 kgf cm 11 ft lbf 7 w Cruise control system REMOVE CRUISE CONTROL ACTUATOR a Disconnect the connector b Remove the 3 bolts and cruise control actuator with the bracket 8 REMOVE STARTER a D...

Page 1262: ...he 5 bolts and disconnect the ground cable Torque 66 N m 670 kgf cm 48 ft lbf 13 REMOVE FRONT WHEELS 14 REMOVE ENGINE UNDER COVER 15 REMOVE LH AND RH FENDER APRON SEALS 16 REMOVE LH AND RH DRIVE SHAFT...

Page 1263: ...bf b Disconnect the shift control cable from the bracket 22 DISCONNECT PS PIPE Remove the 2 bolt and disconnect the PS pipe from the front frame Torque 10 N m 100 kgf cm 7 ft lbf 23 REMOVE LEFT SIDE T...

Page 1264: ...ne hanger 12282 20020 Bolt 91642 80825 Torque 19 5 N m 200 kgf cm 14 ft lbf b Attach the engine chain hoist to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any...

Page 1265: ...ut 21 N m 210 kgf cm 15 ft lbf B bolt 8 0 N m 80 kgf cm 71 in lbf b Turn the crankshaft to gain access to each bolt remove the 6 bolts with holding the crankshaft pulley bolt with a wrench Torque 41 N...

Page 1266: ...e Scuff Plate Combination Switch w Spiral cable Lower No 2 Cover Column Upper Cover Torx Screw Steering Wheel Pad N m kgf cm ft lbf Steering Column Assembly Return Spring 50 510 37 8 8 90 78 in lbf To...

Page 1267: ...pring Shift Lever Steering Column Assembly Parking Lock Cable No 1 11 110 8 2 2 23 19 in lbf 4 4 45 39 in lbf 12 120 9 12 120 9 Parking Lock Cable No 2 Parking Lock Cable Housing AX 18 AUTOMATIC TRANS...

Page 1268: ...nstall the cable housing to steering column assembly with 2 bolts temporarily NOTICE Be careful not to bend or twist the cable abnormally f After installation confirm the following items 1 When the sh...

Page 1269: ...lbf 6 CONFIRMATION OF SHIFT LOCK SYSTEM OPERA TION a Only when the brake pedal is engaged and the ignition key is not at LOCK should the shift lever be able to be shifted from P position to other posi...

Page 1270: ...RING COLUMN ASSEMBLY See page SR 1 1 2 REMOVE PARKING LOCK CABLE a Remove the screw and cable No 2 b Remove the 2 bolts c Using a torx socket wrench remove the 2 screws and cable No 1 3 REMOVE SHIFT L...

Page 1271: ...CONNECTOR 3 REMOVE DIRECT CLUTCH SPEED SENSOR a Remove the bolt and direct clutch speed sensor b Remove the O ring from the direct clutch speed sensor 4 INSTALL DIRECT CLUTCH SPEED SENSOR a Coat a new...

Page 1272: ...TALL LEFT SIDE GEAR SHAFT OIL SEAL a Using SST and a hammer drive in a new oil seal SST 09223 15020 09351 32014 09351 32130 Oil seal depth 0 0 5 mm 0 0 02 in b Coat the lip of the oil seal with MP gre...

Page 1273: ...JUST 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 Torque 6 9 N m 70 kgf cm 61 in lbf c...

Page 1274: ...erter 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 C...

Page 1275: ...5 4 REMOVE VALVE BODY See page AX 6 5 REMOVE THROTTLE CABLE a Remove the bolt and retaining plate b Pull out the cable from the transaxle case 6 INSTALL THROTTLE CABLE If the throttle cable is new pe...

Page 1276: ...CONTROL ACTUATOR a Install the cruise control actuator with the 3 bolts and con nect the connector b Install the battery 10 CONNECT THROTTLE CABLE TO ENGINE Connect the cable to the throttle linkage T...

Page 1277: ...card the gasket 3 REMOVE 3 MAGNETS FROM OIL PAN 4 EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips Look at the chips and particles in the pan and magnet carefully to...

Page 1278: ...manual valve from the manual valve body 7 REMOVE OIL PIPE a Remove the bolt b Pry up both pipe ends with a large screwdriver and re move the 6 pipes 8 DISCONNECT 3 SOLENOID CONNECTORS AND ATF TEMPERAT...

Page 1279: ...1 REMOVE B3 APPLY PIPE Pry up the pipe with a screwdriver and remove the apply pipe 12 REMOVE VALVE BODY a Remove the 9 bolts b Remove the bolt and wire harness clamp c Disconnect the throttle cable f...

Page 1280: ...ve the bolt and shift solenoid valve SL d Remove the O ring from the solenoid valve 16 INSTALL SHIFT SOLENOID VALVE a Coat 2 new O rings with ATF and install them to the shift solenoid valves b Instal...

Page 1281: ...with the bolt Torque 5 5 N m 55 kgf cm 49 in lbf 19 INSTALL VALVE BODY a While holding the cam down with your hand slip the cable end into the slot b Lower the valve body into place NOTICE Do not ent...

Page 1282: ...lbf 22 INSTALL CONNECTOR CLAMP AND PIPE RETAINER a Install the connector clamp with the bolt Torque 11 N m 110 kgf cm 8 ft lbf b Install the pipe retainer with the bolt Torque 11 N m 110 kgf cm 8 ft l...

Page 1283: ...tighten the 2 bolt first Then tighten them with a torque wrench Torque 11 N m 110 kgf cm 8 ft lbf HINT Each bolt length is indicated below Bolt length Bolt A 14 mm 0 551 in Bolt B 37 mm 1 457 in e Ch...

Page 1284: ...or Date 2001 SIENNA RM787U 28 INSTALL OIL PAN WITH NEW GASKET a Install a new gasket and oil pan b Install the 17 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 29 INSTALL DRAIN PLUG Torque 49 N m 500 kgf c...

Page 1285: ...r Bearing Lower Ball Joint Axle Hub Cotter pin Cotter pin Cotter pin Hub Bolt Disc N m kgf cm ft lbf Specified torque Non reusable part Steering Knuckle with Axle Hub 210 2 150 155 107 1 090 79 7 8 80...

Page 1286: ...628 6201 1 2 REMOVE AXLE HUB a Using SST remove the axle hub SST 09520 00031 b Using SST and a press remove the inner race outside from the axle hub SST 09555 55010 09950 60010 09951 00400 09950 70010...

Page 1287: ...T AXLE HUB SA 13 1300 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 9 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 220 AND FRO...

Page 1288: ...and using a torx wrench T30 torque the 4 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 09310 35010 09608 32010 4 INSTALL LOWER BALL...

Page 1289: ...n If the deviation exceeds the maximum replace the bearing 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 Remove the cotter pin and...

Page 1290: ...JOINT FROM LOWER SUSPENSION ARM Remove the 2 nuts and bolt Torque 127 N m 1 300 kgf cm 94 ft lbf 8 REMOVE STEERING KNUCKLE WITH AXLE HUB a Remove the 2 bolts on the lower side of the shock absorb er b...

Page 1291: ...in Lock Cap Dust Cover Center Bearing Inboard Joint Shaft Inboard Joint Shaft Dust Cover LH N m kgf cm ft lbf Specified torque Non reusable part Snap Ring Rear Engine Mounting Insulator ABS Speed Sens...

Page 1292: ...ot clamp b Using a side cutter cut the small inboard and 2 outboard joint boot clamps and remove them 3 REMOVE INBOARD JOINT SHAFT FROM OUTBOARD JOINT SHAFT a Place matchmarks on the inboard and outbo...

Page 1293: ...SIENNA RM787U c Using a press remove the bearing d Remove the snap ring 7 REMOVE NO 2 DUST DEFLECTOR a Mount outboard joint shaft in a soft jaw vise b Using a screwdriver and hammer remove the No 2 d...

Page 1294: ...DRIVE SHAFT SA 23 1310 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 16 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See page DI 220 AND F...

Page 1295: ...new snap ring to the inboard joint shaft b Using SST and a press install a new bearing SST 09223 56010 c Using a snap ring expander install a new snap ring d Using SST and a press install a new dust...

Page 1296: ...INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot pack the outboard joint and boot with grease in the boot kit Grease capacity Color Black 105 125 g 3 7 4 4 oz 7 INSTALL BOOT TO INBOARD JOINT...

Page 1297: ...3 clamps onto the boots f Place SST onto the clamps SST 09521 24010 g Tighten the SST so that the clamps are pinched NOTICE Do not overtighten the SST h Using SST adjust the clearance of the clamps SS...

Page 1298: ...cm 77 ft lbf 2 REMOVE DRIVE SHAFT LOCK NUT a Remove the cotter pin and lock cap b With applying the brakes remove the nut Torque 294 N m 3 000 kgf cm 217 ft lbf 3 DRAIN ATF 4 REMOVE BOLT AND ABS SPEE...

Page 1299: ...g downward Keeping inboard joint shaft in contact with pinion shaft or not can be known from the sound or feeling After installation check that there is 2 3 mm 0 08 0 12 in of play in the axial direct...

Page 1300: ...Cotter pin Lock Cap Cotter pin Front Drive Shaft N m kgf cm ft lbf Specified torque Non reusable part Brake Caliper Steering Knuckle with Axle Hub 210 2 150 155 107 1 090 79 123 1 250 90 7 8 80 69 in...

Page 1301: ...LOWER BALL JOINT 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 one...

Page 1302: ...1 250 kgf cm 90 ft lbf b Install a new cotter pin 2 INSTALL NEW DUST DEFLECTOR Using SST and a hammer install a new dust deflector SST 09316 60011 09316 00011 09316 00041 09608 32010 HINT Align the h...

Page 1303: ...INT 1323 Author Date 2001 SIENNA RM787U REMOVAL 1 REMOVE STEERING KNUCKLE WITH AXLE HUB See page SA 9 2 REMOVE LOWER BALL JOINT a Using a screwdriver remove the dust deflector b Remove the cotter pin...

Page 1304: ...topper Lower Ball Joint N m kgf cm ft lbf Specified torque Non reusable part 206 2 100 152 206 2 100 152 127 1 300 94 127 1 300 94 206 2 100 152 SUSPENSION AND AXLE FRONT LOWER SUSPENSION ARM SA 31 13...

Page 1305: ...SPENSION AND AXLE FRONT LOWER SUSPENSION ARM 1321 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 32 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNM...

Page 1306: ...OINT Remove the 2 nuts and bolt Torque 127 N m 1 300 kgf cm 94 ft lbf 3 REMOVE LOWER SUSPENSION ARM a Remove the 2 bolts on the front side of the lower suspen sion arm Torque 206 N m 2 100 kgf cm 152...

Page 1307: ...IENNA RM787U REPLACEMENT 1 REMOVE LOWER SUSPENSION ARM BUSHING Using SST and a press remove the bushing SST 09649 17010 09710 04081 2 INSTALL LOWER SUSPENSION ARM BUSHING Using SST and a press install...

Page 1308: ...e Non reusable part Bearing Dust Cover Strut Thrust Bearing Front Wiper Arm Cap Cowl Top Ventilator Louver Hood to Cowl Top Seal Outer Front Cowl Stabilizer Bar Link Flexible Hose Bracket Cap ABS Spee...

Page 1309: ...the shock absorber and secure it in a vise b Using SST compress the coil spring SST 09727 30021 NOTICE Do not use an impact wrench It will damage the SST c Using SST to hold the suspension support re...

Page 1310: ...A RM787U DISPOSAL 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 CAUT...

Page 1311: ...27 1314 Author Date 2001 SIENNA RM787U INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sound NOTICE Wh...

Page 1312: ...SUSPENSION AND AXLE FRONT SHOCK ABSORBER 1317 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 25 AFTER INSTALLATION CHECK FRONT WHEEL ALIGNMENT...

Page 1313: ...e coil spring into the gap of the spring low er seat 4 INSTALL UPPER INSULATOR AND SPRING UPPER SEAT a Align the OUT mark of spring upper seat with the mark of the upper insulator b Install the spring...

Page 1314: ...age SA 40 4 REMOVE OUTER FRONT COWL TOP PANEL See page BO 35 5 REMOVE SHOCK ABSORBER WITH COIL SPRING a Loosen the 2 nuts on the lower side of shock absorber Torque 210 N m 2 150 kgf cm 155 ft lbf HIN...

Page 1315: ...g Stabilizer Bar Link Bracket Bushing Cotter Pin Stabilizer Bar Link PS Gear Assembly 19 195 14 39 400 29 39 400 29 181 1 850 134 39 400 29 181 1 850 134 49 500 36 39 400 29 19 195 14 SUSPENSION AND A...

Page 1316: ...R BAR LINK BALL 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...

Page 1317: ...SA084 02 SA 42 SUSPENSION AND AXLE FRONT STABILIZER BAR 1329 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 40...

Page 1318: ...t LH side and white one at RH side 3 DISCONNECT TIE ROD ENDS FROM STEERING KNUCKLE See page SA 9 4 REMOVE LEFT AND RIGHT BRACKETS AND BUSH INGS Remove the 4 bolts 2 brackets and bushings Torque 19 N m...

Page 1319: ...height is not within the specification try to adjust it by pushing down on or lifting the body 2 INSTALL CAMBER CASTER KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow...

Page 1320: ...the 2 nuts e Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required f Tighten the nuts Torque 210 N m 2 150 kgf cm 155...

Page 1321: ...ue Make sure that the length of the left and right rack ends are the same Rack end length difference 1 5 mm 0 059 in or less d Torque the tie rod end lock nuts Torque 74 N m 750 kgf cm 55 ft lbf e Pla...

Page 1322: ...liper and disc b Support the brake caliper securely 3 REMOVE HUB BOLT Using SST remove the hub bolt SST 09628 1001 1 4 INSTALL HUB BOLT Install a washer and nut to the hub bolt as shown in the illustr...

Page 1323: ...rake Drum Assembly Bushing Exhaust Tailpipe Brake Drum Brake Drum ABS Speed Sensor Wire Harness with Brake Line Parking Brake Cable Gasket Rear Brake Drum Assembly 15 155 11 37 380 27 18 185 13 7 8 80...

Page 1324: ...LE REAR AXLE BEAM 1343 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 53 AFTER INSTALLATION BLEED BRAKE SYSTEM See page BR 4 AND CHECK ABS SPEE...

Page 1325: ...nders SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf b Using SST disconnect the right and left brake lines from the flexible hoses and remove the clips and brake lines SST 09023 00100 Torque 15 N...

Page 1326: ...1341 Author Date 2001 SIENNA RM787U 10 REMOVE AXLE BEAM Remove the 2 nuts bolts and axle beam Torque 88 N m 900 kgf cm 65 ft lbf HINT At the time of tightening the nuts adjust the vehicle height by pu...

Page 1327: ...0011 09951 04010 09952 04010 09953 04010 09954 04020 09955 04051 09957 04010 09958 04011 NOTICE If the axle beam has been scratched apply the paint 2 INSTALL BUSHING a Align the matchmarks on the axle...

Page 1328: ...m Hub Bolt Rear Axle Hub N m kgf cm ft lbf Specified torque Non reusable part ABS Speed Sensor Connector 80 820 59 80 820 59 SUSPENSION AND AXLE REAR AXLE HUB SA 43 1330 Author Date 2001 SIENNA RM787U...

Page 1329: ...ENSION AND AXLE REAR AXLE HUB SA 45 1332 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 44 AFTER INSTALLATION CHECK ABS SPEED SENSOR SIGNAL See...

Page 1330: ...e hub and check the backlash in the bearing shaft direction 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 surfac...

Page 1331: ...cm ft lbf Specified torque Non reusable part Cushion Rear Axle Beam Rear Shock Absorber Retainer Cushion Retainer Cushion Retainer Service Hole Cover 25 250 18 37 380 27 37 380 27 SUSPENSION AND AXLE...

Page 1332: ...DISPOSAL 1 FULLY EXTEND SHOCK ABSORBER ROD 2 DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill make a hole near the center of the cylinder as shown in the illustration to discharge the gas insi...

Page 1333: ...87U INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sound If there is any abnormality replace the shock...

Page 1334: ...SA08F 02 SUSPENSION AND AXLE REAR SHOCK ABSORBER SA 51 1338 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page SA 48...

Page 1335: ...tainers and cushion Torque 25 N m 250 kgf cm 18 ft lbf HINT At the time of installation tighten the nut until the screw of the shock absorber protrudes 2 3 mm 0 079 0 118 in c Remove the bolt washer a...

Page 1336: ...eight to the specification 2 INSPECT CAMBER Camber Left right error 0 55 45 0 92 0 75 45 0 75 or less HINT Camber is not adjustable If the measurement is not within the specifications inspect the susp...

Page 1337: ...ACEMENT 1 REMOVE REAR WHEEL 2 REMOVE BRAKE DRUM 3 REMOVE HUB BOLT Using SST remove the hub bolt SST 09628 1001 1 4 INSTALL NEW HUB BOLT Install a washer and nut to the hub bolt as shown in the illustr...

Page 1338: ...ront Rear kPa kgf cm2 psi P205 70R15 95S 240 2 4 35 P215 65R15 95S 240 2 4 35 b Check the tire runout Tire runout 1 0 mm 0 039 in or less 2 ROTATING TIRES HINT See the illustration for where to rotate...

Page 1339: ...shaft direction Maximum 0 05 mm 0 0020 in b Check the axle hub deviation Maximum 0 05 mm 0 0020 in 5 CHECK FRONT SUSPENSION FOR LOOSENESS 6 CHECK STEERING LINKAGE FOR LOOSENESS 7 CHECK BALL JOINT FOR...

Page 1340: ...ring gear Out of adjustment or broken SA 2 SA 4 SA 7 SA 9 SA 43 Bottoming 1 Vehicle Overloaded 2 Spring Weak 3 Shock absorber Worn SA 24 SA 47 SA 24 SA 47 Sways pitches 1 Tire Worn or improperly infla...

Page 1341: ...Cleaner Assembly Cushion Holder ABS Actuator Assembly w ECU Connector N m kgf cm ft lbf 14 140 10 Specified torque 14 140 10 15 155 11 BR 40 BRAKE ABS ACTUATOR 1383 Author Date 2001 SIENNA RM787U ABS...

Page 1342: ...TOR 1385 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 41 HINT After installation fill the brake reservoir with brake fluid bleed brake system...

Page 1343: ...the 6 brake lines from the ABS actuator SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 3 REMOVE ABS ACTUATOR a Disconnect the connector b Remove the 3 nuts and ABS actuator assembly from the brack...

Page 1344: ...Actuator Assembly Air Cleaner Assembly N m kgf cm ft lbf Specified torque 13 130 9 15 155 11 15 155 11 19 6 200 14 5 19 6 200 14 5 13 130 9 13 130 9 BR 44 BRAKE ABS VSC ACTUATOR 1387 Author Date 2001...

Page 1345: ...F13163 N m kgf cm ft lbf Specified torque Oil Pressure Sensor Cushion Holder ABS VSC Actuator Actuator Bracket 13 130 9 20 200 15 Clamp BRAKE ABS VSC ACTUATOR BR 45 1388 Author Date 2001 SIENNA RM787U...

Page 1346: ...BR 47 1390 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 46 HINT After installation fill the brake reservoir with brake fluid bleed brake syst...

Page 1347: ...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...

Page 1348: ...3 REMOVE ABS VSC ACTUATOR ASSEMBLY a Disconnect the 2 connectors b Disconnect the wire harness clamp from the actuator bracket c Remove the 3 nuts and ABS VSC actuator assembly Torque 13 N m 130 kgf...

Page 1349: ...gf cm ft lbf Specified torque Non reusable part 20 205 15 7 8 80 69 in lbf 25 260 19 15 155 11 13 130 9 Brake Master Cylinder Actuator Assembly Brake Line Lower Finish Panel No 1 Safety Pad Insert w o...

Page 1350: ...ll the gasket on the master cylinder b Set the SST on the gasket and lower the pin until its tip slightly touches the piston SST 09737 00010 c w o VSC Set the gasket and ABS actuator bracket on the bo...

Page 1351: ...CONNECT VACUUM HOSE TO BRAKE BOOSTER 7 INSTALL OUTER FRONT COWL TOP PANEL AND 2 COWL TOP VENTILATOR LOUVERS See page BO 35 8 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See page BR 4...

Page 1352: ...pedal and 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...

Page 1353: ...MOVE ABS ACTUATOR ASSEMBLY See page BR 41 4 w VSC REMOVE BRAKE LINES Using SST remove the 2 brake lines SST 09751 36011 5 DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER 6 REMOVE LOWER FINISH PANEL AND NO 1...

Page 1354: ...ecified torque N m kgf cm ft lbf Brake Booster Brake Master Cylinder 10 mm Nut 15 155 11 12 mm Nut 37 375 27 10 mm Nut 15 155 11 12 mm Nut 37 375 27 8 0 82 71 in lbf 13 130 9 13 130 9 5 0 51 44 in lbf...

Page 1355: ...iston and Spring Inlet Union Strainer Reservoir Bracket Cap Gasket Non reusable part Specified torque N m kgf cm ft lbf Clip 5 5 56 49 in lbf 1 8 18 16 in lbf 1 8 18 16 in lbf 10 102 7 Straight Pin Cy...

Page 1356: ...out the inlet union Torque 1 8 N m 18 kgf cm 16 in lbf 3 REMOVE 2 GROMMETS 4 w o VSC REMOVE PISTON STOPPER BOLT a Place the master cylinder in vise b Using a screwdriver push the pistons in all the w...

Page 1357: ...out not at an angle NOTICE If pulled out and installed at an angle there is a possi bility that the cylinder bore could be damaged At the time of reassembly be careful not to damage the rubber lips o...

Page 1358: ...ate 2001 SIENNA RM787U INSPECTION HINT Clean the disassembled parts with compressed air 1 INSPECT CYLINDER BORE FOR RUST OR SCORING If necessary clean or replace the cylinder 2 INSPECT CYLINDER FOR WE...

Page 1359: ...allation is in the reverse order of removal See page BR 14 HINT Before installation adjust length of brake booster push rod See page BR 23 After installation fill the brake reservoir with brake fluid...

Page 1360: ...STER CYLINDER 1361 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 15 NOTICE Apply lithium soap base glycol grease to the rubber parts indicated...

Page 1361: ...m 71 in lbf 5 DISCONNECT BRAKE LINES Using SST disconnect the 2 brake lines from the master cylin der SST 09023 00100 Torque 10 mm nut 15 N m 155 kgf cm 11 ft lbf Torque 12 mm nut 19 6 N m 200 kgf cm...

Page 1362: ...reservoir becomes empty bleed the air from the master cylinder a Disconnect the brake lines from the master cylinder SST 09023 00100 b Slowly depress the brake pedal and hold it c Block off the outlet...

Page 1363: ...peat b and c until all the air in the fluid has been bled out e Repeat the above procedure to bleed the air out of the brake line for each wheel 4 CHECK FLUID LEVEL IN RESERVOIR Check the fluid level...

Page 1364: ...No 1 Safety Pad Insert Lower Finish Panel Pedal Bracket Stop Light Switch 5 0 51 44 in lbf Clip Bushing Cushion Brake Pedal 20 200 15 13 130 9 Bushing 35 360 26 Shift Lock Switch 11 110 8 Pedal Pad C...

Page 1365: ...the stop light switch to lock the nut in the position where the stop light goes off j Push in the brake pedal 5 15 mm 0 20 0 59 in check that stop light lights up k After adjusting the pedal height c...

Page 1366: ...as it could 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 It is very important to keep parts and the area...

Page 1367: ...Piston Seal Piston Cylinder Boot Set Ring Disc brake grease Lithium soap base glycol grease Non reusable part N m kgf cm ft lbf Specified torque Bleeder Plug 29 300 21 Pad Wear Indicator Plate Outer P...

Page 1368: ...ISTON SEAL FROM CYLINDER Using a screwdriver remove the piston seal 4 REMOVE SLIDING PINS AND DUST BOOTS a Remove the 2 sliding pins from the torque plate NOTICE At the time of reassembly please refer...

Page 1369: ...0020 in If the disc s runout is at the maximum value or greater check the bearing play in the axial direction and check the axle hub runout See page SA 9 If the bearing play and axle hub runout are no...

Page 1370: ...R 33 1376 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 29 HINT After installation fill the brake reservoir with brake fluid bleed the brake s...

Page 1371: ...IPER 1375 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 30 NOTICE Apply lithium soap base glycol grease and disc brake grease to the parts ind...

Page 1372: ...disconnect the flexible hose from the caliper Torque 29 N m 300 kgf cm 21 ft lbf HINT At the time of installation install the flexible hose lock securely in the lock hole in the caliper b Use a conta...

Page 1373: ...port Plate Inner Pad Anti squeal Shim Outer Pad Inner Anti squeal Shim Disc brake grease N m kgf cm ft lbf Specified torque 34 350 25 Inner Anti squeal Shim Pad Support Plate BRAKE FRONT BRAKE PAD BR...

Page 1374: ...tallation bolt b Lift up the caliper and suspend it securely HINT Do not disconnect the flexible hose from the caliper 4 REMOVE 2 BRAKE PADS WITH 4 ANTI SQUEAL SHIMS 5 REMOVE 4 PAD SUPPORT PLATES NOTI...

Page 1375: ...ow oil or grease to get on the rubbing face 10 INSTALL CALIPER a Draw out a small amount of brake fluid from the reservoir b Press in the piston with a hammer handle or an equiva lent HINT If the pist...

Page 1376: ...29 300 21 7 8 80 69 in lbf 5 4 55 48 in lbf Front Speed Sensor N m kgf cm ft lbf Specified torque Fender Liner Screw BR 48 BRAKE FRONT SPEED SENSOR 1391 Author Date 2001 SIENNA RM787U FRONT SPEED SEN...

Page 1377: ...BR 50 BRAKE FRONT SPEED SENSOR 1393 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 49 HINT After installation check speed sensor signal See pag...

Page 1378: ...onnect the speed sensor connector 2 REMOVE SPEED SENSOR a Remove the speed sensor from the steering knuckle Torque 7 8 N m 80 kgf cm 69 in lbf b Remove the bolt flexible hose and speed sensor harness...

Page 1379: ...049 Parking Brake Pedal Assembly Parking Brake Switch Parking Brake Cable Clip N m kgf cm ft lbf Specified torque 39 400 29 39 400 29 BRAKE PARKING BRAKE PEDAL BR 9 1352 Author Date 2001 SIENNA RM787U...

Page 1380: ...E PARKING BRAKE PEDAL BR 1 1 1354 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 10 HINT After installation adjust parking brake pedal travel S...

Page 1381: ...ncorrect adjust the parking brake 2 IF NECESSARY ADJUST PARKING BRAKE PEDAL TRAVEL HINT Before adjusting the parking brake make sure that the rear brake shoe clearance has been adjusted For shoe clear...

Page 1382: ...BO 98 2 DISCONNECT PARKING BRAKE SWITCH CONNEC TOR 3 RELEASE PARKING BRAKE PEDAL 4 DISCONNECT PARKING BRAKE WIRE Remove clip and disconnect the parking brake wire 5 REMOVE PARKING BRAKE PEDAL ASSEMBLY...

Page 1383: ...CYLINDER PRESSURE Master cylinder pressure Rear wheel cylinder pressure 2 942 kPa 30 kgf cm2 427 psi 2 942 kPa 30 kgf cm2 427 psi 7 845 kPa 80 kgf cm2 1 138 psi 4 903 kPa 50 kgf cm2 711 psi When inspe...

Page 1384: ...djusting Lever Return Spring Anchor Spring Cap Shoe Hold down Spring Pin Plug Boot Front Shoe High temperature grease Lithium soap base glycol grease Non reusable part N m kgf cm ft lbf Specified torq...

Page 1385: ...un even wear replace the brake shoes HINT If a brake shoe needs replacing the brake shoes must be re placed as a set 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using a brake drum gauge or equivalent measur...

Page 1386: ...to the parts indicated by the arrows See page BR 34 1 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 Che...

Page 1387: ...lowing steps a Insert a screwdriver through the hole in the brake drum and hold the automatic adjusting lever away from the ad juster b Using another screwdriver reduce the brake shoe adjust er by tur...

Page 1388: ...cable from the parking brake lever and remove the rear shoe 6 REMOVE PARKING BRAKE LEVER a Remove the C washer and shim b Remove the parking brake lever 7 REMOVE WHEEL CYLINDER a Using SST disconnect...

Page 1389: ...0J5 03 F02080 Brake Drum Rear Speed Sensor with Rear Axle Hub N m kgf cm ft lbf Specified torque 80 820 59 BRAKE REAR SPEED SENSOR BR 51 1394 Author Date 2001 SIENNA RM787U REAR SPEED SENSOR COMPONENT...

Page 1390: ...BRAKE REAR SPEED SENSOR BR 53 1396 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BR 52 HINT After installation check speed sensor signal See pag...

Page 1391: ...OR 1395 Author Date 2001 SIENNA RM787U REMOVAL 1 DISCONNECT SPEED SENSOR HARNESS a Disconnect the 2 speed sensor connectors b Remove the resin clip holding the sensor harness to the body 2 REMOVE SPEE...

Page 1392: ...Rear brake shoe clearance Out of adjustment 5 Pad or lining Cracked or distorted 6 Piston Stuck 7 Piston Frozen 8 Anchor or return spring Faulty 9 Booster push rod Out of adjustment 10 Vacuum leaks fo...

Page 1393: ...ked or distorted 2 Installation bolt Loose 3 Disc or drum Scored 4 Pad support plate Loose 5 Sliding pin Worn 6 Pad or lining Dirty 7 Pad or lining Glazed 8 Anchor or return spring Faulty 9 Anti squea...

Page 1394: ...to 0 551 in If the belt deflection is not as specified adjust it c Using a belt tension gauge measure the belt tension Belt tension gauge DENSO BTG 20 95506 00020 Borroughs No BT 33 73F Drive belt ten...

Page 1395: ...LOWER VEHICLE 5 START ENGINE Run the engine at idle for a few minutes 6 TURN STEERING WHEEL a With the engine idling turn the wheel to left or right full lock position and keep it there for 2 3 second...

Page 1396: ...ir If the 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 te...

Page 1397: ...from the PS gear See page SR 37 b Connect SST as shown in the illustration below SST 09640 10010 09641 01010 09641 01020 09641 01030 NOTICE Check that the valve of the SST is in the open position c B...

Page 1398: ...become too high g With the engine idling open the valve fully h Measure the fluid pressure at engine speeds of 1 000 rpm and 3 000 rpm Difference fluid pressure 490 kPa 5 kgf cm2 71 psi or less NOTIC...

Page 1399: ...cified torque Non reusable part For use with SST Stabilizer Bar Intermediate Shaft Assembly Clamp Plate Cotter Pin PS Gear Assembly Pressure Feed Tube Return Tube 19 190 14 181 1 850 134 Cotter Pin 49...

Page 1400: ...End Stopper Bushing Oil Seal Oil Seal O ring Wire Specified torque Non reusable part Molybdenum disulfide lithium base grease For use with SST Power steering fluid 74 750 54 83 850 61 60 610 44 83 85...

Page 1401: ...ssure Tube O ring Rack Guide Spring Cap Bearing Gasket Self locking Nut Rack Housing Cap N m kgf cm ft lbf Specified torque Precoated part Molybdenum disulfide lithium base grease Power steering fluid...

Page 1402: ...tubes 3 REMOVE RH AND LH TIE ROD ENDS 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...

Page 1403: ...to the other side HINT Mark the RH and LH rack ends 6 REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST remove the rack guide spring cap lock nut SST 09922 10010 NOTICE Use SST 09922 10010 in the direc...

Page 1404: ...p damage wind vinyl tape on the ser rated part of the control valve shaft b Press out the control valve assembly with the oil seal NOTICE Place a shop rag between the valve housing and the blocks Be c...

Page 1405: ...visible through the service hole SST 09631 10021 b Using SST turn the cylinder end stopper counterclock wise and remove the wire and cylinder end stopper SST 09631 10021 16 REMOVE STEERING RACK AND BU...

Page 1406: ...STEERING GEAR 1438 Author Date 2001 SIENNA RM787U INSPECTION INSPECT STEERING RACK a Using a dial indicator check the steering rack for runout and for teeth wear and damage Maximum runout 0 03 mm 0 0...

Page 1407: ...tubes SST 09023 38400 Torque 27 N m 280 kgf cm 20 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm 11 81 in This torque value is effective in case that SST is parallel to a torque wrenc...

Page 1408: ...POWER STEERING GEAR 1450 Author Date 2001 SIENNA RM787U 12 TORQUE STEERING WHEEL SET NUT Torque 50 N m 510 kgf cm 37 ft lbf 13 INSTALL STEERING WHEEL PAD See page SR 20 14 CHECK FRONT WHEEL ALIGNMENT...

Page 1409: ...ing fluid b Using SST press in the oil seal SST 09950 60010 09951 00240 09951 00430 09952 06010 09950 70010 09951 07360 NOTICE Make sure that the oil seal is installed facing in the correct direction...

Page 1410: ...the slot of the rack housing b Install a new wire into the cylinder end stopper c Using SST turn the cylinder end stopper clockwise 450 50 SST 09631 10021 6 AIR TIGHTNESS TEST a Install SST to the rac...

Page 1411: ...sure that the oil seal is installed facing in the correct direction 10 INSTALL CONTROL VALVE HOUSING WITH CON TROL VALVE ASSEMBLY a Place a new gasket on the rack housing b Align the matchmarks on th...

Page 1412: ...UST TOTAL PRELOAD a To prevent the steering rack teeth from damaging the oil seal lip temporarily install the RH and LH rack ends b Using a hexagon wrench 21 mm torque the rack guide spring cap Torque...

Page 1413: ...ue 50 N m 510 kgf cm 37 ft lbf NOTICE Use SST 09922 10010 in the direction shown in the illustra tion HINT Use a torque wrench with a fulcrum length of 345 mm 13 58 in d Recheck the total preload Prel...

Page 1414: ...is clogged the pressure inside the rack boot will change after it is assembled and the steering wheel is turned b Install the rack boot clip and a new clamp NOTICE Be careful not to damage or twist th...

Page 1415: ...URE TUBES a Coat 4 new O rings with power steering fluid and install them to the 2 turn b Using SST install the pressure tubes SST 09023 38200 Torque 12 N m 120 kgf cm 9 ft lbf HINT Use a torque wrenc...

Page 1416: ...NDS See page SA 9 5 DISCONNECT INTERMEDIATE SHAFT ASSEMBLY See page SR 1 1 6 DISCONNECT CLAMP PLATE Remove the nut and clamp plate 7 DISCONNECT PRESSURE FEED AND RETURN TUBES Using SST disconnect the...

Page 1417: ...50 70010 09951 07200 b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 00180 09951 00320 09952 06010 09950 70010 09951 07200 NOTICE Make sure...

Page 1418: ...0320 09950 70010 09951 07200 3 IF NECESSARY REPLACE OIL SEAL a Using SST remove the oil seal from the bushing SST 09527 2001 1 09612 24014 09613 22011 NOTICE Be careful not to damage the bushing b Coa...

Page 1419: ...a Using a screwdriver remove the teflon rings from the con trol valve assembly NOTICE Be careful not to damage the grooves for the teflon ring b Expand 4 new teflon rings with your fingers NOTICE Be c...

Page 1420: ...eed Tube PS Vane Pump Assembly Gasket Union Bolt Drive Belt Oil Pressure Switch Connector 43 440 32 29 300 22 7 8 80 69 in lbf 25 250 18 27 280 20 21 210 15 52 530 38 43 440 32 Holder Suction Hose SR...

Page 1421: ...Rotor O ring O ring Snap Ring Vane Plate Cam Ring Wave Washer Vane Pump Shaft Vane Pump Pulley Side Plate N m kgf cm ft lbf Specified torque Power steering fluid Non reusable part Oil Seal Straight Pi...

Page 1422: ...REMOVE SUCTION PORT UNION a Remove the bolt and suction port union b Remove the O ring from the suction port union 5 REMOVE PRESSURE PORT UNION FLOW CONTROL VALVE AND SPRING a Remove the pressure por...

Page 1423: ...0 0012 0 0020 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...

Page 1424: ...59035 0 59043 3 44345 26040 14 993 14 995 0 59027 0 59035 4 44345 26050 14 991 14 993 0 59020 0 59027 3 INSPECT FLOW CONTROL VALVE a Coat the flow control valve with power steering fluid and check tha...

Page 1425: ...WER STEERING VANE PUMP 1424 Author Date 2001 SIENNA RM787U 4 INSPECT SPRING Using a vernier calipers measure the free length of the spring Minimum free length 32 3 mm 1 272 in If it is not within the...

Page 1426: ...m 38 ft lbf b Install the oil pressure switch to the union bolt Torque 21 N m 210 kgf cm 15 ft lbf NOTICE Be careful to prevent oil seal from being attached to the connector 2 INSTALL PS VANE PUMP ASS...

Page 1427: ...0 kgf cm 20 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm 11 81 in This torque value is effective in case that SST is parallel to a torque wrench b Install the 2 clamp plates and 2 h...

Page 1428: ...ng 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 V...

Page 1429: ...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 13 N m 130 kgf cm 9 ft lbf 13 INSTALL FR...

Page 1430: ...gear assembly SST 09023 38400 3 REMOVE DRIVE BELT a Using SST loosen the bolt A SST 09249 63010 b Loosen the bolt B 4 REMOVE PS VANE PUMP ASSEMBLY WITH PRES SURE FEED TUBE a Disconnect the connector f...

Page 1431: ...CE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the front housing b Coat a new oil seal lip with power steering fluid c Using...

Page 1432: ...g hazard The SIENNA is equipped with SRS Supplemental Restraint System such as the driver airbag and front passenger airbag Failure to carry out service operation in the correct sequence could cause t...

Page 1433: ...el freeplay Maximum freeplay 30 mm 1 18 in 2 CHECK STEERING EFFORT a Center the steering wheel b Remove the steering wheel pad See page SR 1 1 c Start the engine and run it at idle d Measure the steer...

Page 1434: ...wheel alignment Incorrect 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 2 SR 5 SR 3 SA 4 SA 37 SR 22 SR...

Page 1435: ...ring Transmission Control Cable Assembly Lower LH Finish Panel N m kgf cm ft lbf Specified torque Cowl Side Trim Front Door Inside Scuff Plate Hood Lock Release Lever Clip 35 360 26 25 260 19 8 8 90 7...

Page 1436: ...r Spring Guide Tilt Spring Column Upper Clamp Tapered head Bolt Column Tube Assembly Lower Shaft Bushing Lower Shaft Adapter Non reusable part Molybdenum disulfide lithium base grease N m kgf cm ft lb...

Page 1437: ...Remove the 3 torx screws and shift lever housing 5 REMOVE PARK LOCK CABLE See page AX 19 6 REMOVE RELEASE LEVER SPRING 7 REMOVE TURN SIGNAL BRACKET Remove the 2 torx screws and turn signal bracket 8...

Page 1438: ...adapter from the column tube assembly 11 REMOVE MAIN SHAFT ASSEMBLY a Install SST to the main shaft assembly as shown in the illustration SST 09612 07010 b Using SST compress the compression spring NO...

Page 1439: ...the column upper bracket b Install a new ignition switch with the 2 screws Torque 2 2N m 20kgf cm 17in lbf 5 INSPECT KEY UNLOCK WARNING SWITCH See page BE 15 6 IF NECESSARY REPLACE KEY UNLOCK WARNING...

Page 1440: ...714 STEERING TILT STEERING COLUMN SR 17 1413 Author Date 2001 SIENNA RM787U b Check the bearing rotation condition and check for abnor mal noise If the bearing is worn or damaged replace the column tu...

Page 1441: ...aft assembly and control valve shaft b Install the bolt Torque 35 N m 360 kgf cm 26 ft lbf 5 INSTALL SPIRAL CABLE See page BE 17 6 INSTALL COMBINATION SWITCH WITH SPIRAL CABLE a Install the combinatio...

Page 1442: ...HEEL PAD NOTICE Never use airbag parts from another vehicle When replacing parts replace with new ones Make sure the wheel pad is installed to the specified torque If the wheel pad has been dropped or...

Page 1443: ...ining ring until it fits into the shaft groove NOTICE Do not bend the universal joint of the main shaft assembly more than 20 HINT Hold the main shaft assembly with your hand so that it does not rotat...

Page 1444: ...acket and projection of steering column housing 8 INSTALL RELEASE LEVER SPRING 9 INSTALL PARK LOCK CABLE See page AX 20 10 INSTALL SHIFT LEVER HOUSING Install the shift lever housing with the 3 screws...

Page 1445: ...rench loosen the 2 torx screws until the groove along the screw circumference catches on the screw case c Pull out the wheel pad from the steering wheel and dis connect the airbag connector CAUTION Wh...

Page 1446: ...er b Remove the 3 screws upper and lower column covers 9 REMOVE COMBINATION SWITCH WITH SPIRAL CABLE a Disconnect the 5 connectors b Disconnect the airbag connector c Remove the 3 screws and combinati...

Page 1447: ...OLUMN SR 13 1409 Author Date 2001 SIENNA RM787U 14 REMOVE STEERING COLUMN ASSEMBLY a Loosen the clamp bolt b Disconnect the connectors c Remove the return spring d Remove the 4 column assembly set nut...

Page 1448: ...h Panel No 1 Safety Pad Insert Lower Finish Panel Lower Center Cluster Finish Panel Radio Assembly Center Cluster Finish Panel Front Ash Receptacle Retainer Front Ash Receptacle Box Cowl Side Board Fr...

Page 1449: ...U INSPECTION 1 VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check See page DI 358 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page DI 358 3...

Page 1450: ...r is done with the sensor assembly installed Make sure that the sensor assembly is installed with the specified torque If the sensor assembly has been dropped or there are cracks dents or other defect...

Page 1451: ...owl side boards c No 2 finish panel d Glove compartment e Glove compartment door finish plate f Lower finish panel g No 1 safety pad insert h Center cluster finish panel i Front ash receptacle box j F...

Page 1452: ...llowing cases replace the airbag sensor assembly If the SRS has been deployed in a collision If the airbag sensor assembly has been found to be faulty in troubleshooting If the airbag sensor assembly...

Page 1453: ...Wire Harness RH Front Airbag Sensor Front Airbag Sensor Connector Front Airbag Sensor Connector LH Front Airbag Sensor 20 200 14 20 200 14 RS 56 SUPPLEMENTAL RESTRAINT SYSTEM FRONT AIRBAG SENSOR 1506...

Page 1454: ...COLLISION a Do a diagnostic system check See page DI 358 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 follow...

Page 1455: ...cracks dents or other defects in the case brackets or con nector replace the removed sensor always replace the set bolts with new ones The sensor set bolts have been anti rust treated When the sensor...

Page 1456: ...acing parts replace them with new parts Never reuse the sensor involved in a collision when the SRS has deployed Never repair a sensor in order to reuse it 1 LH REMOVE FRONT AIRBAG SENSOR a Disconnect...

Page 1457: ...deployed in a collision Replace both the left and right airbag sensors If the front airbag sensor has been found to be faulty in troubleshooting If the front airbag sensor has been found to be faulty...

Page 1458: ...Instrument Panel No 1 Safety Pad Retainer No 2 Safety Pad Retainer N m kgf cm ft lbf Specified torque 20 205 15 5 0 51 42 in lbf RS 26 SUPPLEMENTAL RESTRAINT SYSTEM FRONT PASSENGER AIRBAG ASSEMBLY 14...

Page 1459: ...eploys so perform the operation out of doors and where it will not create a nuisance to nearby residents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool Perform the o...

Page 1460: ...of 2 SST to the front passen ger 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 Mov...

Page 1461: ...for scrapping which has a front passenger airbag assembly with deployed air bag use gloves and safety glasses 2 DEPLOYMENT WHEN DISPOSING OF FRONT PAS SENGER AIRBAG ASSEMBLY NOTICE When disposing of...

Page 1462: ...ze Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in 4 Wind the wire harness around the tire tightly CAUTION Make sure that the wire harness is tight It is very...

Page 1463: ...oying HINT Place the SST connector and wire harness inside tires Secure at least 1 m 3 ft of slack for the wire harness f Deploy the airbag 1 Connect the SST red clip to the battery positive terminal...

Page 1464: ...ENNA RM787U Do not apply water etc to a front passenger airbag assembly with the deployed airbag 1 Remove the front passenger airbag assembly from the tire 2 Place the front passenger airbag assembly...

Page 1465: ...tem check See page DI 358 b Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle Check cuts minute cracks or marked discoloration on t...

Page 1466: ...358 b Do a visual check which includes the following items with the front passenger airbag assembly removed from the vehicle Check the deformation or cracks on the instrument panel and instrument pan...

Page 1467: ...que 20 N m 205 kgf cm 15 ft lbf 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 as...

Page 1468: ...the airbag connector take care not to dam age the airbag wire harness c Pull up the connector from the glove compartment door finish plate d Disconnect the front passenger airbag assembly connec tor...

Page 1469: ...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 1470: ...375 27 37 375 27 Side Airbag Assembly Assist Grip Headrest Headrest Support Armrest Seatback Cover with Pad Front Seat Cushion Shield Cup Holder Manual adjuster Snap Ring Reclining Adjuster Knob Recli...

Page 1471: ...ate a nuisance to nearby residents 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 When d...

Page 1472: ...the vehicle NOTICE 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 Ch...

Page 1473: ...See page RS 39 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 air...

Page 1474: ...ion facing inside Tire size Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 in CAUTION Make sure the wire harness is tight It is very danger ous when a loose wire...

Page 1475: ...nectors 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...

Page 1476: ...COLLISION Dispose of the side airbag assembly CAUTION The side airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety...

Page 1477: ...assembly removed from the vehicle Check cuts and cracks of the side airbag assembly Check cuts and cracks in wire harness and chip ping in connectors CAUTION For removal and installation of the seatb...

Page 1478: ...TALL ASSIST GRIP 5 INSTALL FRONT SEAT CUSHION SHIELD a Install the front seat cushion shield with the 2 screws b Employ the same manner described above to the other side 6 INSTALL CUP HOLDER Slide the...

Page 1479: ...the adjusted rearmost position slip off d Tighten the bolts on the front side temporarily from the bolt on the inner side tighten them completely Torque 37 N m 375 kgf cm 27 ft lbf e Slide the seat to...

Page 1480: ...vers and 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 w Manual adjuster REMOVE RE...

Page 1481: ...EATBACK ASSEMBLY Remove the 4 bolts and seatback assembly CAUTION Do not store the seatback assembly with the airbag deploy ment side facing downward 10 REMOVE SEATBACK FRAME a Disengage the hook from...

Page 1482: ...ide airbag assembly has been found to be faulty in troubleshooting Seatback assembly If the side airbag assembly has cuts during checking items See page RS 41 Seatback assembly If the side airbag asse...

Page 1483: ...bf Front Door Scuff Plate Slide Door Scuff Plate Center Pillar Lower Plate Front Seat Outer Belt Retractor Side Airbag Sensor 43 440 32 SUPPLEMENTAL RESTRAINT SYSTEM SIDE AIRBAG SENSOR ASSEMBLY RS 61...

Page 1484: ...SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check See page DI 358 2 Vehicle involved in collision and airbag is not deployed INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check...

Page 1485: ...nnect the connector NOTICE Connection of the connector is done after the sensor assembly has been installed Make sure the sensor assembly is installed with the specified torque If the sensor assembly...

Page 1486: ...ous electrical devices unless absolutely necessary If the IC terminals are touched the IC may be de stroyed by static electricity HINT For step 1 to 4 refer to page BO 108 1 REMOVE SLIDE DOOR SCUFF P...

Page 1487: ...eplace the side airbag sensor assembly If the side airbag assembly has been deployed in a collision If the side airbag sensor assembly has been found to be faulty in troubleshooting If the side airbag...

Page 1488: ...SSENGER AIRBAG ASSEMBLY The inflater 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 and gas generant etc...

Page 1489: ...or safing sensor diagnosis circuit and ignition control drive circuit etc It receives signals from the airbag sensor and judges whether the SRS must be activated or not 8 FRONT AIRBAG SENSOR The front...

Page 1490: ...rbag Sensor Assembly LH Seat Belt Pretensioner LH Side Airbag Assembly LH Squib RS 4 SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG 1454 Author Date 2001 SIENNA RM787U 10 SRS CONNECTORS HINT SRS connectors...

Page 1491: ...g special functions 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...

Page 1492: ...2001 SIENNA RM787U 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 corr...

Page 1493: ...tion sen sor go on simultaneously 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 a...

Page 1494: ...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...

Page 1495: ...Slider SUPPLEMENTAL RESTRAINT SYSTEM SRS AIRBAG RS 9 1459 Author Date 2001 SIENNA RM787U 13 DISCONNECTION OF SIDE AIRBAG CONNECTOR a Place a finger on the slider b Slide the slider to release lock c D...

Page 1496: ...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 As the sli...

Page 1497: ...le connector 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...

Page 1498: ...not deploy the steering wheel pad front passenger airbag assembly side airbag assembly airbag sensor assembly front airbag sen sor and side airbag sensor assembly should be inspected See page RS 14 R...

Page 1499: ...ering Wheel Pad Spiral Cable Column Lower Cover 8 8 90 78 in lbf 34 350 25 N m kgf cm ft lbf Specified torque RS 12 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE 1462 Author Date 2...

Page 1500: ...d which has an undeployed airbag The airbag produces a sizeable exploding sound when it deploys so perform the operation out of doors and where it will not create a nuisance to nearby residents When d...

Page 1501: ...e terminal and the black clip to the battery neg ative terminal HINT Do not connect the yellow connector which will be connected with the supplemental restraint system 2 Check functioning of the SST P...

Page 1502: ...ea around the vehicle 2 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 d Dispose of steering wheel pad...

Page 1503: ...e power source to deploy the airbag a Remove the steering wheel pad See page SR 1 1 CAUTION When storing the steering wheel pad keep the upper sur face of the pad facing upward b Remove the steering w...

Page 1504: ...by 4 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 Alwa...

Page 1505: ...l pad with the pad side facing upward It is very dangerous if the steer ing wheel pad is tied down with the metal surface fac ing upward as the wire harness will be cut by the shock of the airbag depl...

Page 1506: ...aller than the size specified is used the cardboard box will be broken by the shock from the air bag deployment Covering method using tires Place at least 3 tires without disc wheel on top of the disc...

Page 1507: ...for at least 30 minutes af ter deployment Use gloves and safety glasses when handling a steer ing wheel pad with deployed airbag Always wash your hands with water after completing the operation Do no...

Page 1508: ...ce and in the grooved por tion 2 VEHICLE INVOLVED IN A COLLISION AND AIRBAG IS NOT DEPLOYED a Do a diagnostic system check See page DI 358 b Do a visual check which includes the following items with t...

Page 1509: ...N AND AIRBAG IS DEPLOYED a Do a diagnostic system check See page DI 358 b Do a visual check which includes the following items with the steering wheel pad with airbag removed from the ve hicle Check t...

Page 1510: ...RS013 05 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE RS 25 1475 Author Date 2001 SIENNA RM787U INSTALLATION See page SR 20...

Page 1511: ...RS00Z 05 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PAD AND SPIRAL CABLE RS 13 1463 Author Date 2001 SIENNA RM787U REMOVAL See page SR 1 1...

Page 1512: ...spiral cable If the airbag has been deployed If the steering wheel pad or spiral cable has been found to be faulty in troubleshooting If the steering wheel pad steering or spiral cable has been found...

Page 1513: ...corrugated tube and all the connectors in the system are a standard yellow color 1 Vehicles not involved in collision INSPECT SUPPLEMENTAL RESTRAINT SYSTEM Do a diagnostic system check See page DI 358...

Page 1514: ...ly Steering Wheel Pad with Airbag Front Airbag Sensor LH Side Airbag Assembly RH Side Airbag Sensor RH Seat Belt Pretensioner RH Side Airbag Assembly LH Side Airbag Sensor LH Seat Belt Pretensioner LH...

Page 1515: ...any connector has been found to be faulty in troubleshooting If any part of the SRS wire harness or any connector has been found to be faulty during checking items See page RS 67 CAUTION If the wire...

Page 1516: ...reo broadcasts cannot be received even through AM can be received in very clearly Not only does FM stereo have the smallest service area but it also picks up static and other types of interference noi...

Page 1517: ...adually disappear or fade away as the vehicle goes behind a building or other obstruction This is called fade out 4 COMPACT DISC PLAYER Compact Disc Players use a laser beam pick up to read the dig it...

Page 1518: ...type such as a navigation sys tem At the same time the level of customers needs to audio system has been upgraded This lies be hind this standardization The concrete objectives are explained below 1...

Page 1519: ...y When audio system is not equipped with a navigation system audio head unit is the master unit When audio system is equipped with a navigation system radio receiver is the master unit The car audio s...

Page 1520: ...BE0FV 03 I09424 Tweeter Speaker Front Speaker Radio Assembly Front Speaker Amplifier Rear Speaker Steering Switch BODY ELECTRICAL AUDIO SYSTEM BE 139 1657 Author Date 2001 SIENNA RM787U LOCATION...

Page 1521: ...is detected for both System Check Confirmation and Diagnosis Memory Re sponse nCon The Component does not respond to the Diagnosis On Instruction command Applicable to only the system where connected...

Page 1522: ...N ECHN Detail Display Mode Refer to b CHEC CHEC Detail Display Mode Refer to c Physical Address P190 Physical Address P360 OLD OLD Detail Display Mode Refer to d Result Replacing Result Check Result O...

Page 1523: ...NE UP TUNE DOWN P160 SyS 1 1 22 COdE 2 DTC Refer to diagnostic trouble code chart 2 E4 2 Auxiliary Code 2 2 ch5 Along CLr Indicates a switch operation TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP T...

Page 1524: ...ch operation Auxiliary Code 1 Connection Check Code Logical Address 2 Connection Check Code TUNE UP TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN...

Page 1525: ...ck Code TUNE UP TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE DOWN TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP TUNE UP...

Page 1526: ...been discon nected with ignition switch in ACC or ON Check harness for power supply system of component shown by auxiliary code Check harness for communication system of component shown by auxiliary...

Page 1527: ...m bly Check harness for communica tion system of radio receiver as sembly ON OFF Instruction Parameter Error E2 01 Communication Control Error occurs in ON OFF controlling command from radio receiver...

Page 1528: ...for power supply system ofradio receiver assembly Check harness for communication system of radio receiver assembly Check harness for power supply system of stereo component ampli fier Check harness...

Page 1529: ...assembly Registration Request Transmission E3 01 Communication Control Since this DTC is provided for engi neering it may be detected when no actual failure exists Registration Request command is outp...

Page 1530: ...w chart No Radio Radio not operating when power switch turned to ON 1 Display indicates when power switch turned to ON but no sound including noise is produced 2 Noise present but AM FM not operating...

Page 1531: ...No No No No OK OK OK Yes Yes Yes Yes NG NG NG Check if RAD No 1 fuse is OK Radio assembly faulty Replace fuse ACC wire harness faulty Check if GND wire harness side to radio assembly is OK Radio assem...

Page 1532: ...eplace 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 Re...

Page 1533: ...s OK Power amplifier faulty Recheck system after repair Speaker faulty 4 Radio ANY SPEAKER DOSE NOT WORK Is hiss noise produced by non functioning speaker Does continuity exist in speaker wire harness...

Page 1534: ...ssembly 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...

Page 1535: ...ontinuity of the antenna cord OK Check the grounding of the antenna antenna cord choke coil and noise filter See page BE 1 10 Does the condition get better by replacing the choke coil Does the conditi...

Page 1536: ...faulty Can cassette tape be inserted in tape player Check if RADIO No 1 fuse is OK Radio assembly faulty Replace fuse B wire harness faulty GND faulty Power amplifier faulty 8 Radio PRESET MEMORY DISA...

Page 1537: ...OK ACC wire harness faulty Check if RADIO No 1 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...

Page 1538: ...other speaker Function 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...

Page 1539: ...Radio assembly faulty Operates normally after cleaning the heads Yes Function OK if different tape less than 120 mins is inserted Operates normally after cleaning the heads Radio assembly faulty Is t...

Page 1540: ...ormally Check if RADIO No 1 fuse is OK Cassette tape jammed Replace fuse B wire harness faulty Power amplifier faulty Yes Yes Yes Yes No No No No NG OK Radio assembly faulty Is power supplied to B ter...

Page 1541: ...K 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...

Page 1542: ...e 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...

Page 1543: ...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...

Page 1544: ...the noise occur even after pulling out the defogger terminal Does the condition get better by replacing the antenna cord Noise rediates directly to the antenna from the generation source Does the con...

Page 1545: ...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 swit...

Page 1546: ...ce 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 replacement be sure to r...

Page 1547: ...eplace the fuse and check for short circuit c Troubleshoot the clock as follows HINT Inspect the connector on the wire harness side Is there battery positive voltage between terminal B and body ground...

Page 1548: ...allowable error replace the clock c Check that the clock adjusting button is caught in position and does not return If the button is not returned repair or replace the clock d Troubleshoot the clock a...

Page 1549: ...BE1ZH 01 I17265 w o Tachometer Connector A Connectoe B Connector C w Tachometer Connector A Connector C Connectoe B BODY ELECTRICAL COMBINATION METER BE 43 1561 Author Date 2001 SIENNA RM787U CIRCUIT...

Page 1550: ...r SRS Warning Cruise Contorol Indicator Low Air Pressur Warning A B S Circuit ABS Warning VSC Indicator TRC OFF Indicator Illumiation Open Door Warning SLIP Indicator Seat Belt Warning Washer Level Wa...

Page 1551: ...ECU Brake Fluid Level Warning Switch and P K B Switch Airbag Sensor Assembly Retractor Switch IGN Fuse Generator L Terminal ST Fuse Low Oil Pressure Warning Switch Headlight Dimmer Switch Turn Signal...

Page 1552: ...ng Cruise Contorol Indicator Low Air Pressur Warning A B S Circuit ABS Warning VSC Indicator TRC OFF Indicator Illumiation Open Door Warning SLIP Indicator Seat Belt Warning Washer Level Warning O D O...

Page 1553: ...l ECU Brake Fluid Level Warning Switch and P K B Switch Airbag Sensor Assembly Retractor Switch IGN Fuse Generator L Terminal ST Fuse Low Oil Pressure Warning Switch Headlight Dimmer Switch Turn Signa...

Page 1554: ...range 20 18 24 20 17 24 40 38 44 40 38 46 60 56 66 60 57 5 67 80 78 88 80 77 88 100 98 110 100 96 109 120 118 132 120 115 130 140 134 151 5 160 153 173 2 w Tachometer INSPECT TACHOMETER ON VEHICLE a C...

Page 1555: ...ct terminals 1 and 2 on the wire harness side con nector 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 towards the full side...

Page 1556: ...L WARNING LIGHT a Disconnect the connector from the sender gauge b Connect terminals 1 and 3 on the wire harness side con nector c Turn the ignition switch ON check that the warning light lights up If...

Page 1557: ...r gauge re sistance 9 INSPECT ENGINE COOLANT TEMPERATURE RE CEIVER GAUGE RESISTANCE Measure the resistance between terminals Tester connection Resistance A B Approx 175 7 A C Approx 54 0 B C Approx 22...

Page 1558: ...INSPECT BRAKE SYSTEM WARNING LIGHT a Disconnect the connector from the brake fluid warning switch b Release the parking brake pedal c Connect the terminals on the wire harness side of the lev el warni...

Page 1559: ...the switch ON float down If operation is not as specified replace the switch 18 INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch and ground terminal 1 on the wire...

Page 1560: ...at the bulb flushes and the buzzer sounds for 4 8 seconds e Return to step a and operate the buzzer again f Connect the negative lead from the battery to terminal 8 g Check that the buzzer stops sound...

Page 1561: ...Author Date 2001 SIENNA RM787U 23 Passenger seat only INSPECT SEAT BELT WARNING OCCUPANT DETEC TION SENSOR CONTINUITY Check that continuity exists between the terminals 1 and 2 when pressing the sens...

Page 1562: ...witch Engine Room J B No 2 ECU B Fuse DOME Fuse Washer Fluid Level Warning Switch Combination Meter Bulb Check Relay Light Control Rheostat BODY ELECTRICAL COMBINATION METER BE 41 1559 Author Date 200...

Page 1563: ...Courtesy Switch Engine Coolant Temperature Gauge Fuel Sender Gauge Fuel Level Warning Switch Low Oil Pressure Waning Switch Park Neutral Position Switch Door Courtesy Switch BE 42 BODY ELECTRICAL COMB...

Page 1564: ...Disconnect the connector from the inner mirror assembly and inspect the connector on the wire harness side as shown Tester connection Condition Specified condition 6 Ground Constant Continuity 7 Groun...

Page 1565: ...BE1ZP 01 I19479 Electr Chromic Inner Mirror Compass Ignition Switch BE 56 BODY ELECTRICAL COMPASS 1574 Author Date 2001 SIENNA RM787U COMPASS LOCATION...

Page 1566: ...ition differs according to the area where the vehicle will be used it is necessary for each user to set the zone Refer to Compass Zone Map The zone setting can be changed using the comp switch of the...

Page 1567: ...it untouched for several seconds after setting and check that the compass display shows an azimuthal direction N NE E SE S SW W or NW or C 7 CALIBRATION SETTING MODE a Pressing the comp switch for 6 s...

Page 1568: ...r light in switch and test bulb light up for 12 for 18 minutes then the indicator light and test bulb lights go out If operation is not as specified replace the switch 3 Manual Air Conditioning INSPEC...

Page 1569: ...w Mirror Heater INSPECT MIRROR DEFOGGER CIRCUIT a Connect the positive lead from the battery to terminal 4 and the negative lead to terminal 6 b Check that the mirror becomes warm HINT It takes short...

Page 1570: ...ative 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 po...

Page 1571: ...use MIRROR HEATER Fuse Defogger Relay Ignition Switch Defogger Switch Defogger Wire Mirror Defogger w Manual Air Conditioning w Automatic Air Conditioning BE 60 BODY ELECTRICAL DEFOGGER SYSTEM 1578 Au...

Page 1572: ...INNER MIRROR OPERA TION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 b Attach a black colored tape to forward sensor to prevent it from sensing c Lig...

Page 1573: ...9479 Electro Chromic Inner Mirror Driver Side J B NO 1 ECU IG Fuse Ignition Switch BODY ELECTRICAL ELECTRO CHROMIC MIRROR SYSTEM BE 105 1623 Author Date 2001 SIENNA RM787U ELECTRO CHROMIC MIRROR SYSTE...

Page 1574: ...L ENGINE IMMOBILISER SYSTEM BE 159 1677 Author Date 2001 SIENNA RM787U INSPECTION INSPECTION TRANSPONDER KEY COIL CONTINUITY Check that continuity exists between terminal 1 and 2 If continuity is not...

Page 1575: ...18871 Engine Room J B No 2 EFI Fuse Transponder Key Amplifier Transponder Key Coil ECM IGN Fuse Instrument Panel J B BE 158 BODY ELECTRICAL ENGINE IMMOBILISER SYSTEM 1676 Author Date 2001 SIENNA RM787...

Page 1576: ...SYSTEM REGISTRATION PROCEDURE HINT In case of having lost all the already registered master keys you are not able to do additional registration or deletion Change the engine and ECT ECU and then must...

Page 1577: ...er key perform step 1 or 2 without pulling the key out or inserting the already registered key 1 Depress and release brake pedal 5 times or more within 15 sec 2 With the hand held tester require autom...

Page 1578: ...pedal 1 time Security indicator blinks The registration mode completes when pulling out the key and depressing and releasing the brake pedal once or more within 10 secs after indicator has been off or...

Page 1579: ...onal master key is registered Security indicator OFF Within 20 sec Within 10 sec The registration mode completes when pulling out the key and depressing and releasing the brake pedal once or more with...

Page 1580: ...depressing and releasing the brake pedal once or more within 10 sec after in dicator has been off or 10 sec have passed BE 154 BODY ELECTRICAL ENGINE IMMOBILISER SYSTEM 1672 Author Date 2001 SIENNA RM...

Page 1581: ...onal sub key is registered Security indicator OFF Within 20 sec Within 10 sec The registration mode completes when pulling out the key and depressing and releasing the brake pedal once or more within...

Page 1582: ...SURE OF TRANSPONDER KEY CODE There are 2 ways for erasure of transponder key code one way is depressing brake pedal and acceleration pedal and the other way is using hand held tester HINT Delete all o...

Page 1583: ...blinks 3 Remove the master key HINT When the key cannot be pulled out in the step 3 key code deletion is canceled Security indicator is OFF Please follow the screen of the hand held tester for more de...

Page 1584: ...BE052 10 I19463 BODY ELECTRICAL FOG LIGHT SYSTEM BE 27 1545 Author Date 2001 SIENNA RM787U ADJUSTMENT ADJUST FOG LIGHT AIM A bolt Vertical Direction...

Page 1585: ...CONTINUITY Switch position Tester connection Specified condition OFF No continuity ON 10 11 Continuity If continuity is not as specified replace the switch 2 INSPECT FOG LIGHT RELAY CONTINUITY Conditi...

Page 1586: ...y Combination Switch Front Fog Light Switch Engine Room J B NO 2 HEAD Relay DOME Fuse R B NO 7 FOG Fuse H LP LH LO Fuse DIM Relay Ignition Switch BODY ELECTRICAL FOG LIGHT SYSTEM BE 25 1543 Author Dat...

Page 1587: ...k tester made by KENT MORE for this test As it is necessary to record the code of the hand held transmit ter customer s code will be erased When the inspection com pletes please register the customer...

Page 1588: ...DOOR OPENER SWITCH CIRCUIT Disconnect the connector from the switch and inspect the con nector on the wire harness side as shown Tester connection Condition Specified condition 1 Ground Constant Cont...

Page 1589: ...ARAGE DOOR OPENER SYSTEM BE 149 1667 Author Date 2001 SIENNA RM787U INSTALLATION 1 INSTALL GARAGE DOOR OPENER 2 INSTALL FRONT PERSONAL LIGHT a Connect the 2 connectors b Install the 3 screws 3 INSTALL...

Page 1590: ...BE0G3 04 I19478 Engine Room J B NO 2 DOME Fuse Garage Door Opener Switch BODY ELECTRICAL GARAGE DOOR OPENER SYSTEM BE 145 1663 Author Date 2001 SIENNA RM787U LOCATION...

Page 1591: ...egistering the transmitter codes such as for garage or gate check that there is nobody around those places then register a Press the switch for the item to be registered for 20 se conds HINT When tran...

Page 1592: ...is consumed Press the switch of the transmitter repeatedly in registra tion mode as some transmitters stop transmitting for 1 to 2 seconds This system is not applicable to the garage door opener which...

Page 1593: ...nd ON OFF CLEAR DEFAULT MODE PRESSED LOAD DEFAULT LED flashes at a rate of 6 HZ 10 SEC 20 SEC PRESSED ON OFF Enter in erase mode to erase all 3 channels BE 144 BODY ELECTRICAL GARAGE DOOR OPENER SYSTE...

Page 1594: ...ICAL GARAGE DOOR OPENER SYSTEM 1664 Author Date 2001 SIENNA RM787U REMOVAL 1 REMOVE FRONT PERSONAL LIGHT LENS 2 REMOVE FRONT PERSONAL LIGHT a Remove the 3 screws b Disconnect the 2 connectors 3 REMOVE...

Page 1595: ...BE103 04 I02698 For Adjustment in Vertical Direction BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 23 1541 Author Date ADJUSTMENT...

Page 1596: ...o the ground at the position 9 84 ft away from the headlights 3 Ensure that the center line of the vehicle and the paper face forms a 90 degree angle as shown in the illustration 4 Draw a horizontal l...

Page 1597: ...tion Switch Light Control Switch Headlight Dimmer Switch Switch Body Combination Switch Wiper and Washer Switch Spiral Cable BODY ELECTRICAL HEADLIGHTAND TAILLIGHT SYSTEM BE 17 1535 Author Date 2001 S...

Page 1598: ...continuity TAIL 14 16 Continuity HEAD 13 14 16 Continuity AUTO 12 16 Continuity If continuity is not as specified replace the switch 3 INSPECT HEADLIGHT DIMMER SWITCH CONTINU ITY Switch position Teste...

Page 1599: ...auto turn off not in operation Continuity 11 G d Parking brake switch position OFF Parking brake lever released No continuity 11 Ground Parking brake switch position ON Parking brake lever pulled up...

Page 1600: ...the accessory lights up and the headlights turn ON 10 Auto OFF INSPECT AUTOMATIC LIGHT CONTROL a Gradually expose the sensor b Verify that the headlights and the accessory lights come OFF 11 INSPECT L...

Page 1601: ...esponse is too slow turn the knob clockwise 14 w Automatic light control system INSPECT SENSOR CIRCUIT a Disconnect the connector from the sensor and inspect the connector on the wire harness side as...

Page 1602: ...ol switch OFF Vehicle s surroundings are bright Tester connection Condition Specified condition 3 Ground Constant Continuity 1 Ground Ignition switch LOCK or ACC No voltage 1 Ground Ignition switch ON...

Page 1603: ...oom J B No 2 HEAD LH Fuse HEAD RH Fuse DOME Fuse HEAD Relay Engine Room R B No 7 H LP LH Lo Fuse H LP RH Lo Fuse Headlight Dimmer Relay DRL Relay Driver Side J B No 1 TAIL Fuse Taillight Control Relay...

Page 1604: ...w Vanity INSPECT FRONT PARSONAL LIGHT SWITCH CONTI NUITY a Disconnect the connector from the personal light b Push the personal light switch ON check that continuity exists between terminal 1 and 3 c...

Page 1605: ...y exists between terminal 2 and 3 If operation is not as specified replace the switch 5 INSPECT REAR NO 2 INTERIOR LIGHT SWITCH CON TINUITY a Disconnect the connector from the interior light b Turn th...

Page 1606: ...t no continuity exists between terminals and the switch body with the switch OFF switch pin pushed in door closed If operation is not as specified replace the switch 8 INSPECT BACK DOOR COURTESY SWITC...

Page 1607: ...1 Interior Light Door Courtesy Switch Courtesy Light Back Door Courtesy Switch w Power window Except DX Vanity Light Front Interior Light Rear No 2 Interior Light Door Courtesy Switch BE 30 BODY ELECT...

Page 1608: ...NUITY Switch position Tester connection Specified condition LOCK No continuity ACC 2 3 Continuity ON 2 3 4 6 7 Continuity START 1 2 4 6 7 8 Continuity If continuity is not as specified replace the swi...

Page 1609: ...arning Switch Ignition Switch Driver Side J B No 1 Integration Relay BE 14 BODY ELECTRICAL IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH 1532 Author Date 2001 SIENNA RM787U IGNITION SWITCH AND KEY UNL...

Page 1610: ...SWITCH CONTINUITY Switch position Tester connection Specified condition LOCK 3 6 Continuity OFF No continuity UNLOCK 3 5 Continuity If continuity is not as specified replace the switch 3 INSPECT FRONT...

Page 1611: ...Specified condition OFF Door Lock set to LOCK No continuity ON Door Lock set to UNLOCK 3 4 Continuity If continuity is not as specified replace the switch 7 INSPECT FRONT DOOR LOCK MOTOR OPERATION a C...

Page 1612: ...m the battery to terminal 1 and the 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 positi...

Page 1613: ...ration is not as specified replace the door lock assembly 12 INSPECT INTEGRATION RELAY OPERATION HINT When the relay circuit is as specified inspect the door lock sig nal a Connect the positive lead f...

Page 1614: ...Door Key Lock and Unlock Switch Door Lock Control Switch Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Back Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Back Door...

Page 1615: ...condition OFF No continuity UP 4 8 6 7 Continuity DOWN 4 7 6 8 Continuity LEFT 5 8 6 7 Continuity RIGHT 5 7 6 8 Continuity Right side Switch position Tester connection Specified condition OFF No conti...

Page 1616: ...1 2 1 2 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM BE 103 1621 Author Date 2001 SIENNA RM787U b Reverse the polarity check that the mirror turns to right side c Connect the positive lead from the bat...

Page 1617: ...rror Heater 1 2 1 2 BE 104 BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM 1622 Author Date 2001 SIENNA RM787U d Reverse the polarity check that the mirror turns down ward If operation is not as specified...

Page 1618: ...irror Motor Mirror Control Switch Driver Side J B No 1 CIG Fuse Ignition Switch RH Mirror Mirror Motor BODY ELECTRICAL POWER MIRROR CONTROL SYSTEM BE 101 1619 Author Date 2001 SIENNA RM787U POWER MIRR...

Page 1619: ...BE0EX 03 I03187 Power Outlet BODY ELECTRICAL POWER OUTLET BE 13 1531 Author Date 2001 SIENNA RM787U POWER OUTLET LOCATION...

Page 1620: ...4 I18856 Engine Room R B No 1 Engine Room R B No 7 Driver Side J B No 1 Engine Room J B No 2 Engine Room R B No 8 BE 12 BODY ELECTRICAL POWER SOURCE 1530 Author Date 2001 SIENNA RM787U POWER SOURCE LO...

Page 1621: ...e the switch 2 Left side INSPECT POWER VENT WINDOW MOTOR OPERA TION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the window link moves...

Page 1622: ...Window Switch Power Vent Window Motor Driver Side J B NO 1 PWR VENT Fuse POWER Fuse POWER Relay BE 70 BODY ELECTRICAL POWER REAR QUARTER WINDOW SYSTEM 1588 Author Date 2001 SIENNA RM787U POWER REAR Q...

Page 1623: ...ch position Tester connection Specified condition FORWARD 2 12 4 6 Continuity OFF 4 12 4 6 Continuity REAR 2 6 4 12 Continuity If continuity is not as specified replace the switch 2 INSPECT SLIDE MOTO...

Page 1624: ...it takes to shut off the electric current Mo tor opretion sound stops Standard time to shut off about 4 40 secondes c Wait for about 60 seconds after finishing the shut off chesk then oparate the pow...

Page 1625: ...9 Driver Side J B No 1 POWER Fuse Lifter Motor Reclining Motor Power Seat Switch Sliding Motor BE 98 BODY ELECTRICAL POWER SEAT CONTROL SYSTEM 1616 Author Date 2001 SIENNA RM787U POWER SEAT CONTROL SY...

Page 1626: ...2 6 Continuity If continuity is not as specified replace the switch 3 INSPECT POWER SLIDE DOOR LH SIDE CONTROL FRONT SWITCH CONTINUITY Switch position Tester connection Specified condition Switch ON...

Page 1627: ...Open 1 2 No continuity Closed 1 2 Continuity If continuity is not as specified replace the switch 7 INSPECT FUEL LID COURTESY SWITCH CONTINU ITY a Check that continuity exists between terminal 1 and t...

Page 1628: ...e Door MAIN Switch Engine Room J B No 2 Latch Switch Power Slide Door Control ECU Power Slide Door Control Unit Integration Relay Engine Room R B NO 7 PWD SLD Fuse Power Slide Door Control Switch Powe...

Page 1629: ...UP 1 15 6 13 Continuity OFF 1 13 15 Continuity DOWN 1 13 6 15 Continuity Front Passenger s Switch Window lock Switch position Tester connection Specified condition UP 6 13 Continuity OFF 13 15 Contin...

Page 1630: ...the negative lead to terminal 1 and check that the motor turns clockwise b Reverse the polarity check that the motor turns counter clock wise If operation is not as specified replace the motor 6 Passe...

Page 1631: ...r to termi nal 2 on the wire harness side connector and the negative lead to negative terminal of the battery c Connect the positive lead from the battery to terminal 2 on the wire harness side connec...

Page 1632: ...ch and pluse switch 10 Driver s Door INSPECT JAM PROTECTION LIMIT SWITCH OPERA TION a Connect the negative lead from the ohmmeter to ter minal 6 and the positive lead to terminal 4 b Connect the posit...

Page 1633: ...o checking after repeating up and down of the glass with automatic opera tion a Confirmation of AUTO up operation Confirm that the window will be fully close with AUTO up operation b Checking of the o...

Page 1634: ...y ECU IG Fuse Ignition Switch Power Windows Switch Power Window Master Switch Power Window Regulator Assembly Power Window Motor Power Window Regulator Assembly Power Window Motor BE 64 BODY ELECTRICA...

Page 1635: ...ity Hi side 2 4 Continuity Illumination circuit 1 5 Continuity If continuity is not as specified replace the switch 2 INSPECT SEAT HEATER INDICATOR LIGHT OPERA TION a Connect the positive lead from th...

Page 1636: ...uity A3 B1 Constant Continuity If continuity is not as specifies replace the seat cushion pad 4 INSPECT SEAT BACK CONTINUITY Inspect the seat heater back and front cushion continuity be tween terminal...

Page 1637: ...h Driver Side J B NO 1 GAUGE Fuse SEAT HEATER Relay Engine Room R B NO 1 SEAT HTR Fuse Seat Heater Cushion Seat Heater Back BODY ELECTRICAL SEAT HEATER SYSTEM BE 107 1625 Author Date 2001 SIENNA RM787...

Page 1638: ...er connection Specified condition Switch pin free 1 2 Continuity Switch pin pushed in 1 2 No continuity If continuity is not as specified replace the switch 2 w Cruise Control INSPECT STOP LIGHT SWITC...

Page 1639: ...BE0F8 03 I18861 Stop Light Switch Driver Side J B No 1 Stop Fuse Hi Mounted Stop Light Stop Light BE 34 BODY ELECTRICAL STOP LIGHT SYSTEM 1552 Author Date 2001 SIENNA RM787U STOP LIGHT SYSTEM LOCATION...

Page 1640: ...open approx 200 mm 7 87 in No continuity 7 Ground No 2 limit switch ON Except for conditions mentioned above Continuity 4 Ground Ignition switch LOCK or ACC No voltage 4 Ground Ignition switch ON Bat...

Page 1641: ...ity No 2 limit switch ON SW pin pushed in 4 6 Continuity If continuity is not as specified replace the switch 4 INSPECT SLIDING ROOF MOTOR AND LIMIT SWITCH CIRCUIT Disconnect the connector from the li...

Page 1642: ...b With the sliding roof in fully opened position hold the slid ing roof switch in TILT UP position and check that the sliding roof begins to close within 60 seconds If operation is not as specified r...

Page 1643: ...e J B No 1 POWER Fuse GAUGE Fuse DOOR Fuse Power Main Relay Integration Relay Sliding Roof Motor Sliding Roof Control Relay and Switch BE 94 BODY ELECTRICAL SLIDING ROOF SYSTEM 1612 Author Date 2001 S...

Page 1644: ...Headlight Bulb 2 HEAD LO LH RH Fuse E G Room R B No 7 3 Headlight Control Relay E G Room J B No 2 4 Body ECU Integration Relay 5 Light Control Switch 6 Wire Harness BE 18 DI 628 BE 18 Hi Beam does no...

Page 1645: ...NO 7 3 Fog Light Relay 4 Head Relay Engine Room J B NO 2 5 Fog Light Switch 6 Wire Harness BE 26 BE 18 BE 26 Fog light does not light up with light control SW HEAD Headlight does not light 1 1 Other P...

Page 1646: ...ap light does not light up 1 Bulb 2 Front Interior Light 3 Wire Harness BE 31 BACK UP LIGHT SYSTEM Symptom Suspect Area See page Back up Light does not light up 1 Bulb 2 GAUGE Fuse Driver Side J B No...

Page 1647: ...Coolant Temperature Gauge do not operate 1 GAUGE Fuse Driver Side J B No 1 2 Meter Circuit Plate 3 Wire Harness BE 43 Speedometer does not operate 1 ABS ECU 2 Meter Circuit Plate 3 Wire Harness IN 31...

Page 1648: ...ECU B Fuse E G Room J B No 2 2 Bulb 3 Airbag Sensor Assembly 4 Meter Circuit Plate 5 Wire Harness DI 490 BE 43 Open door warning light does not light up 1 DOME Fuse E G Room J B No 2 2 Bulb 3 Door Cou...

Page 1649: ...NTROL SYSTEM Symptom Suspect Area See page Power window does not operate ALL Power Door Lock does not operate 1 POWER Fuse Driver Side J B No 1 2 Power Relay Driver Side J B No 1 3 Wire Harness BE 65...

Page 1650: ...slide door control system and theft deterrent system are operating normally If the trouble still reappears even though there are no abnormalities in any of the other circuits check and replace the Wi...

Page 1651: ...s not operate Door Lock is normal 1 Ignition Switch 2 Sliding Roof Control Relay and Switch 3 Sliding Roof Motor and Limit Switch 4 Wire Harness BE 15 BE 95 BE 95 Sliding roof system operates abnormal...

Page 1652: ...5 Seat Heater BE 108 BE 108 BE 108 Driver s seat heater does not operate 1 Seat Heater Switch D P 2 Wire Harness BE 108 Passenger s seat heater does not operate 1 Seat Heater Switch D P 2 Wire Harness...

Page 1653: ...BODY ELECTRICAL TROUBLESHOOTING BE 1 1 1529 Author Date 2001 SIENNA RM787U ENGINE IMMOBILIZER SYSTEM Symptom Suspect Area See page Engine immobilizer system does not operate See DIAGNOSIS SYSTEM DI 60...

Page 1654: ...lead from the battery to terminal 2 and the negative lead to terminal 3 b Connect the 2 turn signal light bulbs in parallel to each other to terminals 1 and 3 check that the bulbs flash HINT The turn...

Page 1655: ...e J B No 1 Turn Fuse Ignition Switch Combination Switch Turn Signal Switch Turn Signal Light Hazard Warning Switch Turn Signal Flasher BE 28 BODY ELECTRICAL TURN SIGNAL AND HAZARD WARNING SYSTEM 1546...

Page 1656: ...ontinuity INT 7 16 Continuity LO 7 17 Continuity HI 8 17 Continuity Washer ON 2 11 Continuity If continuity is not as specified replace the switch 2 INSPECT INTERMITTENT OPERATION a Turn the wiper swi...

Page 1657: ...nd the negative lead to terminal 2 b Connect the positive lead from the voltmeter to termi nal 7 and the negative lead to terminal 2 c Push in the washer switch and check that the voltage changes as s...

Page 1658: ...8 Low speed INSPECT REAR WIPER MOTOR OPERATION Connect the positive lead from the battery to terminal 3 and negative lead to terminal 2 check that the motor operates at low speed If operation is not a...

Page 1659: ...k continuity between terminals Terminal Specified condition 3 4 Continuity 4 5 No continuity If continuity is not as specified replace the relay 12 INSPECT REAR WIPER RELAY INTERMITTENT OP ERATION a C...

Page 1660: ...Tank Washer Motor Wiper and Washer Switch Driver Side J B No 1 WIPER Fuse Ignition Switch Rear Wiper Motor Rear Wiper Relay BE 36 BODY ELECTRICAL WIPER AND WASHER SYSTEM 1554 Author Date 2001 SIENNA...

Page 1661: ...the battery to the bat tery receptacle side terminal and battery to the bottom termi nal then apply 3 V voltage to the transmitter d In the location where is approx 1 M away from driver s outside han...

Page 1662: ...2 5 V with the battery unloaded is shown on the tester until the energy is completely consumed Accordingly when inspecting the energy amount left in the battery it is necessary to measure the voltage...

Page 1663: ...with the voltage shown at the 3rd time or later g Disconnect the lead h Set the battery lithium battery in the transmitter i Install the cover so that the rubber cover is not distorted or slipped off...

Page 1664: ...nnector to the receiver and in spect the wire harness side connector from the back side as shown Tester connection Condition Specified condition 2 Ground Normal mode 10 14 V 2 Ground Code registration...

Page 1665: ...Door Unlock Detection Switch Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Key Unlock Warning Switch w Theft Deterrent System 1 w Power Slide Door LH PANIC 1 P PWR 1 DOOR D PWR 1 DOO...

Page 1666: ...t 2 Face the transmitter toward the vehicle and press one of transmitter switches for about 1 sec Reference As of the security function even the wireless function is normal there may be the case that...

Page 1667: ...self diagnostic mode within 30 sec within 5 sec 1 2 3 9 10 Key plate inserted Key plate not inserted Ignition switch OK Entered in self diagnosis mode Check in to the Body Control System No NG See Pa...

Page 1668: ...N in the self diagnostic mode the mode returns to normal mode 1 2 or 3 is output 4 is output Buzzer response are same Recognition code registration function check Check that it is possible to enter in...

Page 1669: ...area around vehicle While the transmitting switch is pressed approx 20 secs the taillight flushes continuously After 20 secs repress the switch again No Other body control system faulty Transmitter an...

Page 1670: ...over forcibly HINT Push the cover with a finger as shown in the illustration so that there becomes clearance then pry out the cover from that clearance b Remove the transmitter c Remove the battery li...

Page 1671: ...to erase all previously regis tered codes and register only new recognition codes The confirmation mode is for confirming how many recog nition codes are already registered before you rewrite rec ogn...

Page 1672: ...into the ignition key cylinder then pull it out Press the door lock control switch by manual operation 5 times to LOCK UNLOCK at approx 1 sec interval 1st time 2nd time 3rd time 4th time 5th time LOCK...

Page 1673: ...n relay automatically performs the LOCK UNLOCK operation once or twice at 1 sec interval to inform the operator that rewrite mode has been selected LOCK UNLOCK occurs twice Indicates that rewrite mode...

Page 1674: ...ived first time and second time did not match Proceed to continue registration If even one of the following conditions is satisfied registration of recognition codes is completed 20 secs have elapsed...

Page 1675: ...bf 2 ADJUST DOOR IN FORWARD REARWARD AND VER TICAL DIRECTIONS Loosen the body side hinge bolts and nuts to adjust Torque 19 N m 195 kgf cm 14 ft lbf 3 ADJUST DOOR LOCK STRIKER a Check that the door fi...

Page 1676: ...nse Plate Light Assembly Key Cylinder Rear Combination Light Door Lock Striker Back Door Scuff Plate Rear Combination Light Specified torque N m kgf cm ft lbf Lower Stopper 19 195 14 5 4 55 48 in lbf...

Page 1677: ...tip before use b Remove the screw and pull strap 3 REMOVE CENTER GARNISH Using a screwdriver remove the center garnish HINT Tape the screwdriver tip before use 4 REMOVE SIDE GARNISH a Using a screwdr...

Page 1678: ...he 3 bolts from the wiper motor b Remove the 2 bolts and wiper motor and link assembly Torque 5 4 N m 55 kgf cm 48 in lbf c Remove the grommet 10 REMOVE COMBINATION LIGHTS 11 REMOVE LICENSE PLATE LIGH...

Page 1679: ...R a Disconnect the back door lock locking link from the key cylinder b Disconnect the connector c Remove the 2 bolts and key cylinder Torque 5 5 N m 56 kgf cm 49 in lbf 13 REMOVE BACK DOOR LOCK a Disc...

Page 1680: ...BO0SC 01 BODY BACK DOOR BO 33 1710 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 29...

Page 1681: ...nish LH Side Garnish Wiper Arm Pull Strap Strap Cover Back Door Assist Grip Door Trim board 20 205 15 Specified torque N m kgf cm ft lbf Back Door Glass BO 82 BODY BACK DOOR GLASS 1759 Author Date 200...

Page 1682: ...he adhesive sticking to the glass b Clean the glass with cleaner NOTICE Do not touch the glass surface after cleaning it 3 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush Primer M to the expo...

Page 1683: ...nstall the glass to the body b Use adhesive tape to keep the glass installed tightly against the body NOTICE Take care not to drive the vehicle during the time described in the table below Temperature...

Page 1684: ...ploy the same manner described above to the other side 12 INSTALL BACK DOOR PULL STRAP a Install the pull strap with the screw b Install the strap cover 13 INSTALL BACK DOOR ASSIST GRIP a Install the...

Page 1685: ...pe the screwdriver tip before use b Remove the screw and pull strap 3 REMOVE CENTER GARNISH Using a screwdriver remove the center garnish HINT Tape the screwdriver tip before use 4 REMOVE SIDE GARNISH...

Page 1686: ...he outer surface to keep the surface from being scratched NOTICE When separating the glass take care not to damage the paint and exterior c Cut the adhesive by pulling the piano wire around it HINT Cu...

Page 1687: ...tay is 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 When dr...

Page 1688: ...ding Slide Door Outside Moulding Front Door Outside Moulding Front Fender Outside Moulding Hole Plug Back Door Lower Outside Moulding BODY BODY OUTSIDE MOULDING BO 47 1724 Author Date 2001 SIENNA RM78...

Page 1689: ...adhesive tape from the moulding 3 Wipe off stains with cleaner 4 Apply new adhesive tape to the moulding as shown in the illustration c Install the moulding 1 Using a heat light heat the door and moul...

Page 1690: ...ing release sheet from the face of moulding NOTICE When the moulding release sheet is removed make sure that no dirt or dust can get on to the uncoated area 3 Install the moulding to the door 4 Instal...

Page 1691: ...nstall the moulding 1 Using a heat light heat the body and moulding Body 40 60 C 104 140 F Moulding 20 30 C 68 86 F NOTICE Do not heat moulding excessively 2 Lift the moulding release sheet from the f...

Page 1692: ...r tip before use 2 REMOVE FRONT DOOR OUTSIDE MOULDING a Remove the 2 hole plugs and 2 nuts b Using a heat light heat the moulding to 40 60 C 104 140 F NOTICE Do not heat moulding excessively c Cut the...

Page 1693: ...e not to damage the moulding Do not damage the body d Remove the moulding 4 REMOVE OUTSIDE QUARTER MOULDING Remove the 3 screws and moulding 5 REMOVE BACK DOOR LOWER OUTSIDE MOULDING a Using a heat li...

Page 1694: ...crewdriver Scraper BODY CLIP BO 1 1678 Author Date 2001 SIENNA RM787U CLIP REPLACEMENT The removal and installation methods of typical clips used in body parts are shown in the table below HINT If the...

Page 1695: ...V00012 Shape Example Removal Installation Removal Installation Removal Installation BO 2 BODY CLIP 1679 Author Date 2001 SIENNA RM787U...

Page 1696: ...rcement N m kgf cm ft lbf Specified torque Side Support Side Mounting Bracket Fog Light w Fog light Center Stay 5 4 55 48 in lbf Side Mounting Bracket 5 4 55 48 in lbf 31 320 23 Radiator Grille 7 6 78...

Page 1697: ...N m 260 kgf cm 19 ft lbf 2 ADJUST DOOR IN LEFT RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust HINT Substitute the bolt with washer for the centering bolt Torque 25 N m 260 k...

Page 1698: ...per Armrest Base Panel Regulator Handle Door Trim Courtesy Light Armrest Inside Locking Link Protector Inside Handle Opening Link w o Power door lock w o Power window w o Power window 7 8 80 69 in lbf...

Page 1699: ...ly closed install the plate and regulator handle with the snap ring as shown in the illustration 2 REMOVE INSIDE HANDLE BEZEL a Remove the screw b Using a screwdriver remove the inside handle bezel as...

Page 1700: ...the illustration 9 REMOVE SERVICE HOLE COVER Remove the 2 grommets and cover NOTICE At the time of reassembly please refer to the following item Do not block the trim clip sealing with the service ho...

Page 1701: ...ssembly please refer to the following item Apply MP grease to the window regulator NOTICE At the time of reassembly please refer to the following item Do not apply grease to the spring of the window r...

Page 1702: ...wrench T30 Part No 09042 00010 or locally manufactured tool Torque 4 9 N m 50 kgf cm 43 in lbf HINT Remove the door lock through the service hole HINT At the time of reassembly please refer to the fol...

Page 1703: ...BO0S2 01 BODY FRONT DOOR BO 13 1690 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 8...

Page 1704: ...le Assist Grip Hog Ring Hog Ring Reclining Adjuster Release Handle Seat Cushion Shield Seat Track Upper Rail Cover Seat Track Adjuster Handle Front Seat Inner Belt Seat Cushion Shield Seat Track Upper...

Page 1705: ...ove the 4 bolts 2 bushings and seatback assembly 9 REMOVE SEATBACK COVER a w Assist grip Open the 2 assist grip plugs then remove the 2 screws and assist grip b Remove the headrest c Remove the 2 head...

Page 1706: ...Author Date 2001 SIENNA RM787U INSPECTION INSPECT SLIDING LOCK POSITION SLIPPING OFF When sliding the seat inspect that the outer and inner tracks are locked at the same time HINT When sliding lock p...

Page 1707: ...ing the seat track handle mount the seat to the vehicle HINT If holding the seat track handle the adjusted most front positions slip off c Connect the connector d Tighten the bolts on the rear side te...

Page 1708: ...frame c Install the 2 seat hinge covers d Install the 2 headrest supports e Install the headrest f w Assist grip Install the assist grip with the 2 screws g w Assist grip Install the 2 assist grip plu...

Page 1709: ...s the wire harness between the seat cushion and loop handle e Connect the connector and clamp the wire harness as shown in the illustration 9 INSTALL SEAT TRACK UPPER RAIL COVERS 10 INSTALL SEAT CUSHI...

Page 1710: ...NNA RM787U REMOVAL REMOVE FRONT SEAT a Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use b Remove the 4 bolts Torque 37 N m 380 kgf cm 27 ft lbf c Disconnect th...

Page 1711: ...e fastened to the seat heater then remove the seat heater b Seatback cover Cut the 8 tack pins which are fastened to the seat heater then remove the seat heater 6 INSTALL NEW SEAT HEATER a Set a new s...

Page 1712: ...nt a a Seat Cushion Cover Listing Pocket a a Seat Wire Tack Pin Seat Heater Correct Incorrect Seat Heater Tack Pin Seat Wire Tack Pin Seat Heater Seat Wire Mark Indication BODY FRONT SEAT Manual Adjus...

Page 1713: ...Mark Indication Seatback Cover Listing Pocket a a Seat Wire Tack Pin Seat Heater Correct Incorrect Seat Heater Tack Pin Seat Wire Tack Pin Seat Heater Seat Wire Upper BO 130 BODY FRONT SEAT Manual Ad...

Page 1714: ...shion cover Install the 3 seat wires to the seat cushion cover b Seatback cover Install the 2 seat wires to the seatback cover HINT Pass the wire over the seat heater as shown in the illustration 8 RE...

Page 1715: ...er Seat Switch Seat Cushion Shield Power Switch Knob Seat Track Upper Rail Cover 18 185 13 18 185 13 Specified torque N m kgf cm ft lbf Non reusable part 43 440 32 Center Armrest Cover Center Armrest...

Page 1716: ...BLY Remove the 4 bolts and seatback assembly 9 REMOVE SEATBACK COVER a Remove the 2 assist grip plugs 2 screws and assist grip b Remove the headrest c Remove the 2 headrest supports d Remove the 2 sea...

Page 1717: ...BO0TV 01 BODY FRONT SEAT Power Adjuster Type BO 123 1800 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 1 15...

Page 1718: ...back frame c Install the 2 seat hinge covers d Install the 2 headrest supports e Install the headrest f Install the assist grip with the 2 screws g Install the 2 assist grip plugs 4 INSTALL SEATBACK A...

Page 1719: ...SIENNA RM787U d Pass the wire harness between the seat cushion and bracket of the adjuster e Connect the connector 7 INSTALL POWER SEAT SWITCH 8 INSTALL SEAT TRACK UPPER RAIL COVERS 9 INSTALL SEAT CU...

Page 1720: ...NA RM787U REMOVAL REMOVE FRONT SEAT a Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use b Remove the 4 bolts Torque 37 N m 380 kgf cm 27 ft lbf c Disconnect the...

Page 1721: ...re fastened to the seat heater then remove the seat heater b Seatback cover Cut the 8 tack pins which are fastened to the seat heater then remove the seat heater 6 INSTALL NEW SEAT HEATER a Set a new...

Page 1722: ...nt a a Seat Cushion Cover Listing Pocket a a Seat Wire Tack Pin Seat Heater Correct Incorrect Seat Heater Tack Pin Seat Wire Tack Pin Seat Heater Seat Wire Mark Indication BO 1 18 BODY FRONT SEAT Powe...

Page 1723: ...Mark Indication Seatback Cover Listing Pocket a a Seat Wire Tack Pin Seat Heater Correct Incorrect Seat Heater Tack Pin Seat Wire Tack Pin Seat Heater Seat Wire Upper BODY FRONT SEAT Power Adjuster T...

Page 1724: ...hion cover Install the 3 seat wires to the seat cushion cover b Seatback cover Install the 2 seat wires to the seatback cover HINT Pass the wire over the seat heater as shown in the illustration 8 REV...

Page 1725: ...098 in BODY FRONT WIPER AND WASHER BO 39 1716 Author Date 2001 SIENNA RM787U ADJUSTMENT ADJUST WASHER NOZZLE Using a tool like the one shown in the illustration change the direction of the nozzle hole...

Page 1726: ...No 1 Cowl Water Extract Hose No 2 Cowl Water Extract Hose Wiper Link Wiper Motor Cowl Panel Hole Cover Specified torque N m kgf cm ft lbf 7 4 75 65 in lbf 20 205 15 7 8 80 69 in lbf 7 4 75 65 in lbf...

Page 1727: ...e washer fluid hits the windshield and the surge area are with in the range indicated by the hatched line A Approx 150 mm 5 91 in B Approx 50 mm 1 97 in C Approx 0 50 mm 0 1 97 in D Approx 120 mm 4 72...

Page 1728: ...uter front cowl top panel Torque 7 4 N m 75 kgf cm 65 in lbf 4 INSTALL OUTER FRONT COWL TOP PANEL Connect the wiper motor connector then install the panel with 11 bolts Torque 7 8 N m 80 kgf cm 69 in...

Page 1729: ...tor louver then disconnect the washer hose b Remove the clip and LH cowl top ventilator louver then disconnect the washer hose 5 REMOVE WASHER NOZZLE a Remove the washer nozzle from the cowl top venti...

Page 1730: ...WASHER BO 37 1714 Author Date 2001 SIENNA RM787U 8 REMOVE WIPER MOTOR a Disconnect the wiper link from the wiper motor b Remove the 3 screws and wiper motor 9 REMOVE NO 1 COWL WATER EXTRACT HOSE 10 R...

Page 1731: ...ot be adjusted with it on Substitute the bolt with washer for the centering bolt 1 ADJUST HOOD IN FORWARD REARWARD AND LEFT RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts Torq...

Page 1732: ...r Finish Panel Front Ash Receptacle Retainer Front Ash Receptacle Box Glove Compartment Front Door Scuff Plate Cowl Side Board Front Door Opening Trim Cover Radio Assembly Clock Front Pillar Garnish F...

Page 1733: ...ssembly Instrument Panel Wire Instrument Panel No 3 Register D 7 20 205 15 D D D D D D D D D D D 5 0 51 44 in lbf 5 0 51 44 in lbf Specified torque N m kgf cm ft lbf D Light Control Switch Hole Cover...

Page 1734: ...L 15 0 63 8 0 31 6 0 24 8 0 31 Shape Shape Size L 20 0 79 6 0 24 Size BO 100 BODY INSTRUMENT PANEL 1777 Author Date 2001 SIENNA RM787U HINT Screw shapes and sizes are indicated in the table below The...

Page 1735: ...ag 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 one b Pry off the 5 clips and remove the front p...

Page 1736: ...BO0TK 01 BO 106 BODY INSTRUMENT PANEL 1783 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 101...

Page 1737: ...BO0TJ 01 BODY INSTRUMENT PANEL BO 105 1782 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 104...

Page 1738: ...nector c Employ the same manner described above to the other side 5 REMOVE STEERING WHEEL PAD See page SR 1 1 6 REMOVE STEERING WHEEL See page SR 1 1 7 REMOVE STEERING COLUMN COVER See page SR 1 1 8 R...

Page 1739: ...tor NOTICE When handling the airbag connector take care not to dam age the airbag wire harness 13 REMOVE GLOVE COMPARTMENT Remove the 3 nuts 2 screws and glove compartment 14 REMOVE CENTER CLUSTER FIN...

Page 1740: ...the connectors HINT Tape the screwdriver tip before use c Remove the 2 screws and heater blower switch from the panel d Remove the clock 19 REMOVE COMBINATION METER 20 REMOVE RADIO ASSEMBLY 21 REMOVE...

Page 1741: ...BO0SO 02 H02657 Roof Drip Side Finish Moulding BODY ROOF DRIP SIDE FINISH MOULDING BO 53 1730 Author Date 2001 SIENNA RM787U ROOF DRIP SIDE FINISH MOULDING COMPONENTS...

Page 1742: ...c Wipe off stains with cleaner 2 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat the contact surface on the body with primer M NOTICE Let the primer coating dry for 3 minutes or more Do...

Page 1743: ...soapy water to contact surface of the moulding as shown in the illustration b Using a heat light heat the body and moulding Body 40 60 C 104 140 F Moulding 20 30 C 68 86 F NOTICE Do not heat moulding...

Page 1744: ...H02693 Windshield Upper Moulding Roof Drip Side Finish Moulding BODY ROOF DRIP SIDE FINISH MOULDING BO 57 1734 Author Date 2001 SIENNA RM787U Insert the moulding securely as shown in the illustra tion...

Page 1745: ...164 2 REMOVE ROOF DRIP SIDE FINISH MOULDING a Using a heat light heat the moulding to 40 60 C 104 140 F NOTICE Do not heat moulding excessively b Cut the adhesive tape with a knife NOTICE Do not damag...

Page 1746: ...et No 3 Side Bracket Rear Bumper Cover No 2 Side Bracket Energy Absorber Rear Bumper Reinforcement 6 8 70 61 in lbf 31 320 23 31 320 23 N m kgf cm ft lbf Specified torque BODY REAR BUMPER BO 5 1682 Au...

Page 1747: ...Lock Reclining Connecting Pipe Rear Seat Reclining Cover Reclining Adjuster Reclining Adjuster Release Handle Rear Seat Cushion Under Cover Armrest Cover Armrest Seat Leg Hog Ring Hog Ring 37 380 27...

Page 1748: ...lining Connecting Pipe Rear Seat Reclining Cover Reclining Adjuster Reclining Adjuster Release Handle Hog Ring Hog Ring 43 440 32 43 440 32 18 185 13 43 440 32 18 185 13 Specified torque N m kgf cm ft...

Page 1749: ...the 4 bolts and reclining adjusters from the seatback assembly 8 REMOVE SEATBACK COVER a Pull of the reclining connecting pipe from the seatback assembly b Remove the 2 headrests c Remove the 3 clips...

Page 1750: ...or Date 2001 SIENNA RM787U INSPECTION INSPECT RECLINING LOCK POSITION When reclining the seat inspect that the outer and inner tracks are released at the same time HINT When the reclining lock positio...

Page 1751: ...b Install the seatback frame c Install the 4 headrest supports d w CRS Install the child restraint seat e w CRS Install the child restraint seat cover f Install the seatback board with 3 clips g Inst...

Page 1752: ...t Adjuster Rear No 1 Seat Inner Belt Reclining Connecting Pipe Seatback Pad Seatback Hinge Cover Seat Cushion Cover Seat Cushion Pad Seat Cushion Frame Reclining Adjuster Release Handle Hog Ring Hog R...

Page 1753: ...he reclining connecting pipe sub assembly c Remove the hooks of the seatback cover d Remove the 2 headrest supports e Remove the seatback frame from the seatback cover with pad f Remove the seatback c...

Page 1754: ...OFF a When reclining the seat inspect that the outer and inner tracks are released at the same time HINT When the reclining lock positions slip off disassemble the seat to adjust the positions b When...

Page 1755: ...ALL REAR NO 1 SEAT HINGES AND RECLINING CONNECTING PIPE Install the rear No 1 seat hinge with 4 bolts and reclining connecting pipe another with 2 bolts Torque 18 N m 185 kgf cm 13 ft lbf 7 INSTALL SE...

Page 1756: ...elt Reclining Connecting Pipe Rear No 1 Seat Hinge Seatback Pad Seatback Hinge Cover Seat Cushion Cover Seat Cushion Pad Reclining Adjuster Release Handle Hog Ring Hog Ring Center Armrest Center Armre...

Page 1757: ...bly b Remove the hooks of the seatback cover c Remove the headrest d Remove the 2 headrest supports e Remove the seatback frame from the seatback cover with pad f Remove the seatback cover from the se...

Page 1758: ...OFF a When reclining the seat inspect that the outer and inner tracks are released at the same time HINT When the reclining lock positions slip off disassemble the seat to adjust the position b When s...

Page 1759: ...4 bolts Torque 18 N m 185 kgf cm 13 ft lbf 7 INSTALL REAR NO 1 SEAT HINGES AND RECLINING CONNECTING PIPE Install the rear No 1 seat hinge with 4 bolts and reclining connecting pipe with another 2 bolt...

Page 1760: ...pe Rear No 2 Seat Inner Belt Seat Leg Cover Seat Cushion Under Cover Specified torque N m kgf cm ft lbf Non reusable part Release Handle Hog Ring Hog Ring 43 440 32 43 440 32 43 440 32 19 195 14 43 44...

Page 1761: ...sembly b Remove the headrest c Remove the 2 clips and seatback board d Remove the headrest supports e Remove the seatback frame f Remove the seatback cover from the seatback pad 6 REMOVE SEAT LEG COVE...

Page 1762: ...BO0UE 01 BO 150 BODY REAR NO 2 SEAT 1827 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 149...

Page 1763: ...Panel Speaker Grille Front Door Scuff Plate Lower Center Pillar Garnish Front Door Opening Trim Cover Slide Door Scuff Plate Front Pillar Garnish Rear Window Side Garnish Cowl Side Board Quarter Trim...

Page 1764: ...BO3Y8 01 BODY ROOF HEADLINING BO 1 13 1790 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 108...

Page 1765: ...5 REMOVE REAR LH QUARTER TRIM PANEL a Using a screwdriver remove the speaker grille HINT Tape the screwdriver tip before use b Remove the quarter trim cover c Using a screwdriver remove the rear side...

Page 1766: ...emove the rear side trim board cov er HINT Tape the screwdriver tip before use d Remove the slide door courtesy light then disconnect the connector e Remove the 2 screws clip and RH quarter trim panel...

Page 1767: ...T PILLAR GARNISH a Using a screwdriver remove the front pillar garnish HINT Tape the screwdriver tip before use b w Tweeter speaker Disconnect the connector c Employ the same manner described above to...

Page 1768: ...anner described above to the other side 17 REMOVE COAT HOOKS 18 REMOVE ASSIST GRIPS 19 REMOVE SUN VISORS AND HOLDERS 20 w Sliding roof REMOVE SLIDING ROOF OPENING TRIM MOULDING 21 REMOVE ROOF CONSOLE...

Page 1769: ...ng a screwdriver remove the lens HINT Tape the screwdriver tip before use b Remove the 4 screws and rear No 2 room light then dis connect the connector 25 REMOVE ROOF HEADLINING a Using a screwdriver...

Page 1770: ...Slide Door Scuff Plate w o Power vent window Quarter Window Lock Rear Side Window Rear Side Window Weatherstrip Speaker Grille Courtesy Light w Power vent window Power Vent Window Motor w Power vent w...

Page 1771: ...BO0T2 02 BODY REAR SIDE WINDOW GLASS LH BO 77 1754 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 75...

Page 1772: ...HINT Tape the screwdriver tip before use 4 REMOVE REAR LH QUARTER TRIM PANEL a Using a screwdriver remove the speaker grille HINT Tape the screwdriver tip before use b Remove the quarter trim cover c...

Page 1773: ...at outer belt shoulder anchor Torque 43 N m 440 kgf cm 32 ft lbf b Remove the 2 clips and LH rear window side garnish 7 w Power vent window REMOVE REAR SIDE WINDOW a Disconnect the power vent window m...

Page 1774: ...ndow Lock Hinge Back Door Scuff Plate No 2 RH Rear Window Side Garnish Coat Hook Assist Grip RH Rear Window Side Garnish No 6 Rear Air Duct RH Quarter Trim Panel Courtesy Light Slide Door Scuff Plate...

Page 1775: ...BO0T5 01 BODY REAR SIDE WINDOW GLASS RH BO 81 1758 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 79...

Page 1776: ...ove the 10 screws and RH and LH No 3 rear air ducts b Remove the 4 screws and No 5 rear air duct c Remove the No 6 rear air duct 3 w Power vent window REMOVE REAR SIDE WINDOW a Disconnect the power ve...

Page 1777: ...57 Author Date 2001 SIENNA RM787U 4 w o Power vent window REMOVE REAR SIDE WINDOW a Remove the 2 bolts 2 nuts and rear side window b Remove the screw and quarter window lock from the rear side window...

Page 1778: ...d Back Door Assist Grip Strap Cover Back Door Pull Strap Specified torque N m kgf cm ft lbf 5 4 55 48 in lbf 5 4 55 48 in lbf Wiper Arm Wiper Motor and Link Assembly 5 4 55 48 in lbf BODY REAR WIPER A...

Page 1779: ...RM787U INSPECTION INSPECT REAR WASHER NOZZLE While operating the washer check if the point where the washer fluid hits the back door glass is within the range indicated by the hatched line A Approx 1...

Page 1780: ...the grommet b Install the wiper motor and link assembly with 5 bolts Torque 5 4 N m 55 kgf cm 48 in lbf c Connect the connector 3 INSTALL BACK DOOR TRIM BOARD Install the door trim board to the back...

Page 1781: ...ap cover 7 INSTALL BACK DOOR ASSIST GRIP a Install the back door assist grip with the 2 screws b Close the covers 8 INSTALL WIPER ARM a Operate the wiper once and turn the wiper switch OFF b Install t...

Page 1782: ...p before use b Remove the 2 screws and assist grip 3 REMOVE BACK DOOR PULL STRAP a Using a screwdriver remove the strap cover HINT Tape the screwdriver tip before use b Remove the screw and back door...

Page 1783: ...r trim board to pry the door trim board out NOTICE Be careful not to damage the door and door trim board HINT Tape the screwdriver tip before use b Pull the door trim board to remove it 7 REMOVE WIPER...

Page 1784: ...AL CAUTION Never dispose of front seat outer belt which has inac tivated pretensioner The seat belt pretensioner produces a sizeable ex ploding sound when it activates so perform the op eration out of...

Page 1785: ...ip of the SST to the battery posi tive terminal and the black clip to the battery neg ative terminal HINT Do not connect the yellow connector which will be connected with the seat belt pretensioner 2...

Page 1786: ...d front seat outer belt 6 Connect the 2 SST each other then connect them to the seat belt pretensioner SST 09082 00700 09082 00740 NOTICE To avoid damaging the SST connector and wire harness do not lo...

Page 1787: ...seat out er belt still installed 2 ACTIVATION WHEN DISPOSING OF FRONT SEAT OUTER BELT ONLY NOTICE When disposing of the front seat outer belt with seat belt pretensioner only never use the customer s...

Page 1788: ...ess the SST activation switch and activate the seat belt pretensioner HINT The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up e Dispose of the front s...

Page 1789: ...he center pillar lower garnish Check for cuts and cracks in wire harness and for chipping in connectors Check for deformation of the center pillar CAUTION For removal and installation of the front sea...

Page 1790: ...n installing the front seat outer belt take care that the wiring does not interfere with other parts and is not pinched between other parts 1 INSTALL RETRACTOR OF FRONT SEAT OUTER BELT a Install the r...

Page 1791: ...thor Date 2001 SIENNA RM787U 4 INSTALL REAR NO 1 SEAT OUTER BELT SHOULDER ANCHOR a Install the rear No 1 seat outer belt shoulder anchor with the bolt Torque 43 N m 440 kgf cm 32 ft lbf b Install the...

Page 1792: ...at outer belt shoulder anchor 3 REMOVE SLIDE DOOR SCUFF PLATE 4 REMOVE LOWER CENTER PILLAR GARNISH a Remove the bolt and front seat outer belt floor anchor b Remove the lower center pillar garnish 5 R...

Page 1793: ...lt pretensioner has been activated If the seat belt pretensioner has been found to be faulty in troubleshooting If the front seat outer belt has been found to be faulty during the check in items 1 b o...

Page 1794: ...oard Cover Window Garnish Upper No 1 Trim Cover Door Trim Cup Holder Slide Door Glass Upper No 2 Trim Cover Dam Non reusable part BODY SLIDE DOOR GLASS BO 67 1744 Author Date 2001 SIENNA RM787U SLIDE...

Page 1795: ...f all the adhesive has been removed clean the body 2 CLEAN REMOVED GLASS a Remove the damaged stoppers and dams b Using a scraper remove the adhesive sticking to the glass c Clean the glass with clean...

Page 1796: ...mer M NOTICE Let the primer coating dry for 3 minutes or more Do not coat primer M to the adhesive Do not keep any of the opened primer M for later use 6 COAT CONTACT SURFACE OF GLASS WITH PRIMER G a...

Page 1797: ...0 mm 0 315 in C 15 0 mm 0 59 in D 17 0 mm 0 67 in E 34 5 mm 1 36 in F 18 5 mm 0 73 in 8 INSTALL GLASS a Install the glass to the door b Hold the glass in place securely with a protective tape or equi...

Page 1798: ...R NO 2 TRIM COVER Install the upper No 2 trim cover to the slide door panel 12 INSTALL UPPER NO 1 TRIM COVER Install the upper No 1 trim cover to the slide door panel 13 INSTALL DOOR TRIM a Install th...

Page 1799: ...e trim out NOTICE Be careful not to damage the door and door trim HINT Tape the screwdriver tip before use c Pull the trim to remove it 3 REMOVE UPPER NO 1 TRIM COVER Using a screwdriver remove the up...

Page 1800: ...surface to keep the surface from being scratched NOTICE When separating the glass take care not to damage the paint and exterior c Cut the adhesive by pulling the piano wire around it HINT Cut the adh...

Page 1801: ...15 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 43 440 32 Rear No 2 Seat Outer Belt Rear No 1 Seat Inner Belt Anchor Cap Hol...

Page 1802: ...llowing static check Also 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 q...

Page 1803: ...200 mm 7 87 in of belt remains retracted 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 I...

Page 1804: ...310 kgf cm 22 ft lbf 2 ADJUST DOOR IN VERTICAL DIRECTION Loosen the lower roller mounting bolts to adjust Torque 30 N m 310 kgf cm 22 ft lbf 3 ADJUST DOOR IN FORWARD REARWARD DIREC TION Loosen the up...

Page 1805: ...are adjusted correctly b Loosen the striker mounting screw Torque 23 N m 230 kgf cm 17 ft lbf c Using a plastic hammer tap the striker to adjust 8 ADJUST CONTROL CABLE TENSION a Pull on the rear side...

Page 1806: ...h white marks and hold the position HINT Instead of 2 screwdrivers 2 round sticks diameter 12 13 mm 0 47 0 51 in is more useful for the operation e Turn the adjusting bolt counterclockwise by approx 3...

Page 1807: ...cm ft lbf 23 230 17 7 0 71 62 in lbf 9 8 100 7 9 8 100 7 x 6 Upper Rail Cushion Rear Door Check Cover Rear Lock Striker Rear No 1 Seat Outer Belt 43 440 32 Center Roller w Power slide door Power Slid...

Page 1808: ...ndow Garnish Door Trim Cup Holder Inside Handle Service Hole Cover Specified torque N m kgf cm ft lbf Precoated Part 5 5 56 49 in lbf 30 310 22 4 9 50 43 in lbf 8 0 82 71 in lbf 4 9 50 43 in lbf Upper...

Page 1809: ...out NOTICE Be careful not to damage the door and door trim HINT Tape the screwdriver tip before use c Pull the trim to remove it 3 REMOVE UPPER NO 1 TRIM COVER Using a screwdriver remove the upper No...

Page 1810: ...ock control as sembly b Disconnect the connector c Remove the clip d Remove the 3 screws Torque 4 9 N m 50 kgf cm 43 in lbf HINT At the time of reassembly please refer to the following item Apply adhe...

Page 1811: ...uiva lent 14 REMOVE OUTSIDE HANDLE a Disconnect the link and cable b Remove the 2 bolts and outside handle c Remove the retainer and key cylinder from the outside handle 15 REMOVE SLIDE DOOR CONTROL M...

Page 1812: ...ease to the sliding surface of the slide door lock control assembly Using an air riveter or hand riveter install the slide door lock control assembly to the door frame with the rivets NOTICE At the ti...

Page 1813: ...It is necessary to initialize the system in the following procedures Other wise slide door cannot be operated normally Disconnect the battery negative terminal for more than 1 min and install it Close...

Page 1814: ...BO0S7 01 BO 26 BODY SLIDE DOOR 1703 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 19...

Page 1815: ...e use d w o Power slide door Remove the bolt and center rail protector Torque 9 8 N m 100 kgf cm 7 ft lbf e Remove the upper rail cushion f w Power slide door Remove the 2 bolts from the slide door g...

Page 1816: ...onnect the control cables 8 w Power slide door REMOVE POWER SLIDE DOOR DRIVE UNIT a Disconnect the connectors b RH Remove the bolt 7 nuts and power slide door drive unit c LH Remove the 8 nuts and pow...

Page 1817: ...H02636 BO 18 BODY SLIDE DOOR 1695 Author Date 2001 SIENNA RM787U 10 REMOVE LOWER STEP PLATE Remove the 3 screws 2 clips and lower step plate...

Page 1818: ...LIDING ROOF GLASS FORWARD OR REARWARD a Using a torx wrench loosen the sliding roof glass installa tion screws b Adjust the sliding roof glass forward or rearward 3 ADJUST SLIDING ROOF GLASS IN CLEARA...

Page 1819: ...nish Front Door Opening Trim Cover Front Door Scuff Plate Quarter Trim Cover Lower Center Pillar Garnish Courtesy Light Roof Side Garnish Heater Control Panel Slide Door Scuff Plate Speaker Grille Qua...

Page 1820: ...Housing Drive Gear Sunshade Trim Sliding Roof Panel Stopper Mounting Bracket Sliding Roof Rail Specified torque N m kgf cm ft lbf Mounting Bracket Mounting Bracket 5 5 56 49 in lbf 4 0 41 36 in lbf 5...

Page 1821: ...as shown in the illustration 4 REMOVE REAR FRAME Remove the 4 screws and rear frame 5 REMOVE DRIVE CABLE a Remove the screw and guide rail stopper b Slide the drive cable rearward then remove it HINT...

Page 1822: ...ROOF 1771 Author Date 2001 SIENNA RM787U 7 REMOVE GUIDE BLOCK a Remove the 2 screws and guide block b Employ the same manner described above to the other side 8 REMOVE SLIDING ROOF HOUSING Remove the...

Page 1823: ...BO0TF 01 BODY SLIDING ROOF BO 97 1774 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page BO 91...

Page 1824: ...check 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...

Page 1825: ...BO0TE 01 BO 96 BODY SLIDING ROOF 1773 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page BO 93...

Page 1826: ...ver tip before use b Employ the same manner described above to the other side 3 REMOVE SLIDING ROOF GLASS a Using a torx wrench remove the 2 screws Torque 4 0 N m 41 kgf cm 36 in lbf b Employ the same...

Page 1827: ...er and screw NOTICE At the time of installation please refer to the following item If the sliding roof position and drive gear full close position are not matched the sliding roof does not operate nor...

Page 1828: ...driver airbag front pas senger airbag and side airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a...

Page 1829: ...oulding Outside Moulding Wiper Arm RH Cowl Top Ventilator Louver Hood to Cowl Top Seal LH Cowl Top Ventilator Louver No 2 Dam Specified torque N m kgf cm ft lbf Non reusable part 20 205 15 Front Door...

Page 1830: ...emoved clean the body 2 CLEAN REMOVED GLASS a Using a scraper remove the adhesive sticking to the glass b Clean the glass with cleaner NOTICE Do not touch the glass surface after cleaning it 3 REPLACE...

Page 1831: ...Check that all contacting parts of the glass rim are perfect ly even and do not make contact with the fasteners c Place reference marks between the glass and body d Remove the glass 7 CLEAN CONTACT S...

Page 1832: ...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...

Page 1833: ...s 20 C 68 F 5 hours 5 C 41 F 24 hours 12 INSPECT FOR LEAK AND REPAIR a Conduct a leak test after the hardening time has elapsed b Seal any leak with sealant Part No 08833 00030 or equivalent 13 APPLY...

Page 1834: ...TOP SEAL 18 INSTALL WIPER ARMS a Operate the wipers once and turn the wiper switch OFF b Install the wiper arms and tighten nuts by hand c Adjust the installation position of the wiper arms to the po...

Page 1835: ...ape the screwdriver tip before use b w Tweeter speaker Disconnect the connector c Employ the same manner described above to the other side 5 REMOVE SUN VISORS AND HOLDERS 6 REMOVE ASSIST GRIP 7 w Slid...

Page 1836: ...e clip and LH cowl top ventilator louver then disconnect the washer hose 15 REMOVE OUTSIDE MOULDING a Attach the rivet cutter to the drill b Gently and vertically put the drill to the rivet and cut th...

Page 1837: ...to the outer surface to keep the surface from being scratched NOTICE When separating the glass take care not to damage the paint and interior and exterior ornaments To prevent scratching the safety pa...

Page 1838: ...l A C Control Assembly Upper Cluster Finish Panel Center Cluster Finish Panel AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Auto A C AC 1 15 1956 Author Date 2001 SIENNA RM787U AIR CONDITIONING C...

Page 1839: ...AC3DU 01 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Auto A C AC 1 17 1958 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 1 16...

Page 1840: ...C 1957 Author Date 2001 SIENNA RM787U REMOVAL 1 REMOVE UPPER CLUSTER FINISH PANEL 2 REMOVE CENTER CLUSTER FINISH PANEL 3 REMOVE INSTRUMENT CLUSTER FINISH PANEL See page BO 101 4 REMOVE A C CONTROL ASS...

Page 1841: ...C Switch Knob Heater Control Name Plate Heater Control Base Air Mix Control Cable Color Yellow Water Valve Control Cable Color Green Mode Control Cable Color Balck Upper Cluster Finish Panel Radio Re...

Page 1842: ...ase the 4 claws and remove the A C switch from the heater control name plate 4 REMOVE BLOWER SWITCH a Pull out the 2 bulbs b Disconnect the 2 bulb holders c Remove the 2 screws and blower switch 5 REM...

Page 1843: ...d check that the A C indicator lights up If operation is not as specified replace the A C switch c Connect the positive lead from the battery to terminal 3 and check that the indicator dims If operati...

Page 1844: ...er speed control switch Illumination circuit If continuity is not as specified replace the bulb 4 INSPECT FRESH RECIRC SWITCH INDICATOR OP ERATION a Connect the positive lead from the battery to termi...

Page 1845: ...ATE 1 8 Continuity Defroster Def Foot and Foot mode switch OFF No continuity Illumination circuit 5 7 Continuity If continuity is not as specified replace the fresh recirc switch 7 Air flow selector I...

Page 1846: ...OOL position 2 Mode control dial at DEF position b Adjust air mix control cable 1 Set air mix damper control lever to COOL position 2 Install inner cable to lever pin and clamp the outer cable HINT Lo...

Page 1847: ...ONDITIONING CONTROL ASSEMBLY Manual A C ON VEHICLE INSPECTION INSPECT A C CONTROL DIAL OPERATION Turn the control dials left and right then check that click sound can be heard and recoil is felt If cl...

Page 1848: ...AC0VJ 02 AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY Manual A C AC 125 1966 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 121...

Page 1849: ...ANEL 5 REMOVE INSTRUMENT CLUSTER FINISH PANEL 6 REMOVE LOWER NO 2 FINISH PANEL 7 REMOVE GROVE COMPARTMENT 8 REMOVE CONTROL INSTRUMENT CLUSTER FINISH PANEL 9 REMOVE RADIO RECEIVER ASSEMBLY See pgae BO...

Page 1850: ...AC0TW 02 AC 136 AIR CONDITIONING AIR CONDITIONING AMPLIFIER Manual A C 1977 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 135...

Page 1851: ...Continuity A11 A15 Evaporator temperature at 25 C 77 F Approx 1 5 k A16 A15 Constant 65 125 at 20 C 68 F B5 B4 Temperature control dial at Max COOL Approx 6 0 k B5 B4 Temperature control dial at Max...

Page 1852: ...dle up speed Below 0 7 V Refrigerant pressure 196 3 140 kPa Battery positive voltage A3 Ground Refrigerant pressure less than 196 kPa or more than 3 140 kPa No voltage A9 G d Magnetic clutch is engage...

Page 1853: ...ONING AIR CONDITIONING AMPLIFIER Manual A C AC 135 1976 Author Date 2001 SIENNA RM787U REMOVAL 1 REMOVE LOWER NO 2 FINISH PANEL See page BO 101 2 REMOVE A C AMPLIFIER a Disconnect the connector b Remo...

Page 1854: ...g cylinder CAUTION Do not open both high and low pressure 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...

Page 1855: ...is being charged with liquid refrigerant a Open the high pressure and valve fully b Charge specified amount of refrigerant then close the high pressure hand valve HINT A fully charged system is indica...

Page 1856: ...ect adapter 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 a...

Page 1857: ...adiator Blower Unit Blower Motor Manual A C A C Amplifier Relay Block No 4 Front Heater Relay Front Cooling Unit Blower Resistor Evaporator Expansion Valve Thermistor Evaporator Temp Sensor Rear Blowe...

Page 1858: ...Motor Manual A C Blower Resistor Air Mix Servomotor Rear M1 Relay Rear Relay Rear M2 Relay Rear LO Relay Manual A C Relay Block No 3 Heater Radiator Auto A C Rear Heater Intake air Temp Sensor Auto A...

Page 1859: ...perature between compressor inlet and outlet is noticeably different Correct or too much Refer to items 5 and 6 5 Immediately after air conditioning is turned off refrigerant in sight glass stays clea...

Page 1860: ...refrigeration system freezes at expansion valve orifice and blocks circulation of refriger ant 1 Replace receiver 2 Remove moisture in cycle through repeatedly evacuating air 3 Charge proper amount o...

Page 1861: ...Refrigerant does not circulate Symptom seen in refrigeration system Probable cause Diagnosis Remedy Vacuum indicated on low pres sure side very low pressure indi cated on high pressure side Frost or d...

Page 1862: ...per formance due to excessive refrig eration system Insufficient cooling of condenser Excessive refrigerant in cycle refrigerant over charged Condenser cooling condenser fins clogged of condenser fan...

Page 1863: ...piping on low pressure side Trouble in expansion valve Excessive refrigerant in low pressure piping Expansion valve opened too wide 1 Check expansion valve 2 Check heat sensing tube installed conditi...

Page 1864: ...ing in the refrigeration system When compressor is OFF Approx 392 588 kPa 4 6 kgf cm2 57 85 psi b Bring the gas leak detector close tor the drain hose before performing the test HINT After the blower...

Page 1865: ...AINER OR EXPOSE IT TO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPL PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not...

Page 1866: ...traint System 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...

Page 1867: ...VE AIR INLET TEMPERATURE SENSOR a Slide the floor carpet backward b Disconnect the connector c Remove the screw and air inlet temperature sensor 7 INSPECT AIR INLET TEMPERATURE SENSOR CIR CUIT See pag...

Page 1868: ...OTOR a Disconnect the wire harness clamp b Disconnect the connector c Remove the 3 screws and air mix servomotor 7 INSPECT AIR MIX SERVOMOTOR CIRCUIT See page DI 736 8 INSPECT AIR MIX DAMPER POSITION...

Page 1869: ...EMOVE AIR MIX SERVOMOTOR a Slide the floor carpet backward b Disconnect the connector c Remove the 2 screws and servomotor 7 Manual A C INSPECT SERVOMOTOR OPERATION a Connect the positive lead from th...

Page 1870: ...position Approx 4 8 k 3 4 Lever at WARM position Approx 1 2 k If resistance is not as specified replace the servomotor 9 Auto A C INSPECT REAR AIR MIX DAMPER POSITION SEN SOR CIRCUIT See page DI 733 1...

Page 1871: ...ERT 3 REMOVE AIR OUTLET SERVOMOTOR a Disconnect the connector b Remove the 3 screws and air outlet servomotor then dis connect the control link 4 INSPECT AIR OUTLET SERVOMOTOR CIRCUIT See page DI 744...

Page 1872: ...MBIENT TEMPERATURE SENSOR Auto A C INSPECTION 1 REMOVE AMBIENT TEMPERATURE SENSOR a Disconnect the connector b Using a screwdriver pull out the ambient temperature sensor HINT Tape the screwdriver tip...

Page 1873: ...inforcement Blower Unit A C Amplifier Cooling Unit ECM Blower Case Blower Motor Non reusable part No 1 Brace No 2 Brace Air Inlet Servomotor AC 54 AIR CONDITIONING BLOWER UNIT 1895 Author Date 2001 SI...

Page 1874: ...6 AIR CONDITIONING BLOWER UNIT 1897 Author Date 2001 SIENNA RM787U DISASSEMBLY 1 REMOVE BLOWER MOTOR Remove the 3 screws and blower motor 2 REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and air inle...

Page 1875: ...b Check the motor arm rotates counterclockwise and arm stops on the FRESH position c Connect the positive lead of the battery to terminal 5 and negative lead to terminal 1 d Check the motor arm rotat...

Page 1876: ...AC0UU 01 AIR CONDITIONING BLOWER UNIT AC 59 1900 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 55...

Page 1877: ...AC0UT 01 AC 58 AIR CONDITIONING BLOWER UNIT 1899 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 56...

Page 1878: ...UMENT PANEL AND REINFORCE MENT See page BO 98 3 REMOVE ECM Remove the 3 bolts and ECM 4 REMOVE BLOWER UNIT a Remove the wire harness clamp b Remove the screw and A C amplifier with cooler bracket c Di...

Page 1879: ...EMOVE BLOWER MOTOR LINEAR CONTROLLER a Disconnect the connector b Remove the 2 screws and blower motor linear controller 3 INSPECT BLOWER MOTOR LINEAR CONTROLLER See page DI 765 If resistance is not a...

Page 1880: ...250 18 18 185 13 18 185 13 Pressure Plate Shim Rotor Stator Compressor Snap Ring 13 2 135 9 N m kgf cm ft lbf Specified torque Non reusable part Drive Belt Adjusting Bar Bracket Discharge Hose Compres...

Page 1881: ...MBLY 1 REMOVE 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 a...

Page 1882: ...ing item The snap ring should be installed so that beveled side faces up 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 RE...

Page 1883: ...AC0951 Stator AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH AC 65 1906 Author Date 2001 SIENNA RM787U c Remove the stator...

Page 1884: ...8 ft lbf Nut 25 N m 250 kgf cm 18 ft lbf 2 INSTALL GENERATOR a Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt Do not tighten the bolts yet b Connect the generator...

Page 1885: ...7 5 CONNECT NEGATIVE TERMINAL CABLE TO BAT TERY 6 EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount 1 050 50 g 37 03 1 76 oz 7 INSPECT FOR LEAKAGE OF REFRIGERANT Usin...

Page 1886: ...cified replace the compressor assem bly 4 INSPECT VISUAL FOR LEAKAGE OF REFRIGERANT FROM SAFETY SEAL Using a gas leak detector check for leakage of refrigerant If there is any leakage replace the comp...

Page 1887: ...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...

Page 1888: ...8 6 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 7 REMOVE GENERATOR a Dis...

Page 1889: ...RELAY Marking FAN NO 2 FROM ENGINE ROOM R B NO 1 3 REMOVE NO 3 COOLING FAN RELAY Marking FAN NO 3 FROM ENGINE ROOM R B NO 1 4 INSPECT NO 1 FAN RELAY CONTINUITY Condition Tester connection Specified c...

Page 1890: ...FAN RELAY 1949 Author Date 2001 SIENNA RM787U 6 INSPECT NO 3 FAN RELAY CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B between terminals 1 and 2 3 5 Continui...

Page 1891: ...AC0SY 01 AIR CONDITIONING CONDENSER AC 75 1916 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 62...

Page 1892: ...AMAGE If 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 COND...

Page 1893: ...ied amount 1 050 50 g 37 03 1 76 oz 2 DISCONNECT LIQUID TUBE AND DISCHARGE HOSE a Remove the bolt and disconnect the discharge hose Torque 10 N m 100 kgf cm 7 ft lbf b Loosen the nut and disconnect th...

Page 1894: ...ts from condenser brackets b Push the radiator toward engine c Push the condenser toward radiator and pull it upward HINT At the time of installation please refer to the following item If condenser is...

Page 1895: ...AC0TL 02 I04726 Upper Radiator Hose Fan Shroud Clip Fan Fan Motor Condenser Fan Non reusable part AC 1 10 AIR CONDITIONING CONDENSER FAN 1951 Author Date 2001 SIENNA RM787U COMPONENTS...

Page 1896: ...n NOTICE When removing the clip and fan do not apply too much force to the motor shaft And do not scrach the motor shaft HINT At the time of the reassembly please refer to the following item Install a...

Page 1897: ...AC0TP 01 AC 1 14 AIR CONDITIONING CONDENSER FAN 1955 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse orser of removel See page AC 1 11...

Page 1898: ...temperature 95 C 203 F or above Rotate High speed Refrigerant perssure 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 Rot...

Page 1899: ...AC0TO 01 AIR CONDITIONING CONDENSER FAN AC 1 13 1954 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 1 12...

Page 1900: ...11 1952 Author Date 2001 SIENNA RM787U REMOVAL 1 DRAIN ENGINE COOLANT FROM RADIATOR HINT It is not necessary to drain out all the coolant 2 DISCONNECT RADIATOR UPPER HOSE 3 REMOVE CONDENSER FAN a Dis...

Page 1901: ...AIR CONDITIONING DRIVE BELT AC 19 1860 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 18 AFTER INSTALLATION CHECK DRIVE BELT S INSTALLATION CO...

Page 1902: ...the drive belt fits properly in the ribbed grooves 2 INSPECT DRIVE BELT TENSION Using a belt tension gauge check the drive belt tension Drive belt tension New belt 165 26 lbf Used belt 88 22 lbf HINT...

Page 1903: ...DRIVE BELT 1859 Author Date 2001 SIENNA RM787U REMOVAL REMOVE DRIVE BELT a Loosen the pivot bolt and adjusting lock bolt Torque Pivot bolt 56 N m 570 kgf cm 41 ft lbf Adjusting lock bolt 18 N m 185 kg...

Page 1904: ...s continuity replace the switch b Using an ohmmeter check that there is continuity be tween the switch terminals when the coolant temperature is below 88 C 190 F If there is no continuity replace the...

Page 1905: ...nect the connector b Remove the 3 screws and blower motor 4 INSPECT BLOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 then check that...

Page 1906: ...OR a Disconnect the connector b Remove the 2 screws and blower resistor 3 INSPECT BLOWER RESISTOR RESISTANCE Tester connection Condition Specified condition 1 3 Constant Approx 1 56 1 4 Constant Appro...

Page 1907: ...AC0UZ 01 AIR CONDITIONING FRONT A C HEATER RADIATOR AC 77 1918 Author Date 2001 SIENNA RM787U INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air...

Page 1908: ...AC0V0 01 AC 78 AIR CONDITIONING FRONT A C HEATER RADIATOR 1919 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 76...

Page 1909: ...ant 2 REMOVE INSTRUMENT PANEL 3 REMOVE REINFORCEMENT See page BO 101 4 REMOVE DEFROSTER NOZZLE See page AC 42 5 REMOVE HEATER RADIATOR a Remove the screw and piping clamp b Remove the 2 screws 2 clamp...

Page 1910: ...or Thermistor Evaporator Temp Sensor Cooling Unit Case Drain Hose B l o w e r Resistor Cooling Unit Case O Ring Holder 22 225 16 32 330 24 14 140 10 10 100 7 Packing N m kgf cm ft lbf Specified torque...

Page 1911: ...er 3 SEPARATE COOLING UNIT CASES a Using a knife cut off each packing HINT At the time of reassembly please refer to the following item Do not reuse the packing b Remove the 6 screws then separate the...

Page 1912: ...e the expansion valve Torque Expansion valve x Evaporator 22 N m 225 kgf cm 16 ft lbf Expansion valve x Liquid tube 14 N m 140 kgf cm 10 ft lbf HINT At the time of reassembly please refer to the follo...

Page 1913: ...fins are clogged clean them with compressed air NOTICE Never use water to clean them the evaporator 2 INSPECT FITTINGS FOR CRACKS OR SCRATCHES If necessary repair or replace 3 INSPECT THERMISTOR RESI...

Page 1914: ...AC0UK 01 AC 32 AIR CONDITIONING FRONT COOLING UNIT 1873 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 27...

Page 1915: ...nstall the blower resistor e Install the lower No 2 finish panel See page BO 106 2 INSPECT EXPANSION VALVE a Check quantity of gas during refrigeration cycle b Set on manifold gauge set c Run engine 1...

Page 1916: ...AC0UJ 01 AIR CONDITIONING FRONT COOLING UNIT AC 31 1872 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 28...

Page 1917: ...TUBES Remove the 2 bolts and disconnect the both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT At the time of insta...

Page 1918: ...RONT HEATER RELAY INSPECTION 1 REMOVE LOWER NO 2 FINISH PANEL See page BO 101 2 REMOVE FRONT HEATER RELAY FROM RELAY BLOCK NO 4 3 INSPECT FRONT HEATER RELAY CONTINUITY Condition Tester connection Spec...

Page 1919: ...Brace Grommet Wireless Door Lock ECU Theft Deterrent ECU Air Duct Cooling Unit Non reusable part Packing Water Hose Wire harness Wire harness Heater Radiator Pipe Auto A C Air Mix Servomotor Auto A C...

Page 1920: ...n connect the control link b Remove the 2 screws c Release the 2 claws and remove the duct 2 REMOVE COVER 3 REMOVE HEATER RADIATOR a Remove the 2 screws and 2 clamps b Pull out the heater radiator c R...

Page 1921: ...AC0UP 01 AC 46 AIR CONDITIONING FRONT HEATER UNIT 1887 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 42...

Page 1922: ...AC0UO 01 AIR CONDITIONING FRONT HEATER UNIT AC 45 1886 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 44...

Page 1923: ...DIATOR PIPES a Using pliers grip the claws of the hose clips and slide the clip along the hose b Disconnect the water hoses from heater radiator pipes HINT At the time of installation please refer to...

Page 1924: ...UNIT AC 43 1884 Author Date 2001 SIENNA RM787U b Release the 2 claws and remove the air duct 7 REMOVE HEATER UNIT Remove the 2 rivets and heater unit HINT At the time of installation please refer to t...

Page 1925: ...1 CLOSE BOTH 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 t...

Page 1926: ...Tighten the nuts by hand CAUTION Do not connect the wrong hoses 2 CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4 REMOVE C...

Page 1927: ...REMOVE REAR RH QUARTER TRIM PLATE See page BO 79 5 REMOVE POWER TRANSISTOR a Disconnect the connector b Remove the 2 screws and power transistor 6 INSPECT POWER TRANSISTOR See page DI 772 7 INSTALL PO...

Page 1928: ...GARNISH See page BO 108 6 REMOVE POWER TRANSISTOR a Slide the floor carpet backward b Disconnect the connector c Remove the 2 screws and power transistor 7 INSPECT POWER TRANSISTOR See page DI 768 a...

Page 1929: ...AC0TT 01 AIR CONDITIONING PRESSURE SWITCH AC 101 1942 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 100...

Page 1930: ...T See page AC 20 2 DISCONNECT CONNECTOR FROM PRESSURE SWITCH 3 RUN ENGINE AT APPROX 1 500 RPM 4 Magnetic clutch control INSPECT PRESSURE SWITCH OPERATION a Connect the positive lead from the ohmmeter...

Page 1931: ...efrigerant and inspect for refrigerant Specified amount 1 050 50 g 37 03 1 76 oz 2 REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch Torque 10 N m 100 kgf...

Page 1932: ...ol Name Plate Heater Control Heater Blower Switch Heater Control Bulb Knob Assembly Base Manual A C only AIR CONDITIONING REAR A C CONTROL ASSEMBLY AC 127 1968 Author Date 2001 SIENNA RM787U REAR A C...

Page 1933: ...AR A C CONTROL ASSEMBLY AC 129 1970 Author Date 2001 SIENNA RM787U DISASSEMBLY 1 REMOVE HEATER CONTROL KNOBS 2 Manual A C only REMOVE HEATER BLOWER SWITCH a Remove the bulb b Disconnect the bulb holde...

Page 1934: ...ation circuit If continuity is not as specified check the bulb 2 Manual A C INSPECT SELECT SWITCH OPERATION a Gradually turn the select switch from the WARM to COOL side then check that the resistance...

Page 1935: ...AC0U9 02 AC 132 AIR CONDITIONING REAR A C CONTROL ASSEMBLY 1973 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 128...

Page 1936: ...AC0U8 02 AIR CONDITIONING REAR A C CONTROL ASSEMBLY AC 131 1972 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 129...

Page 1937: ...r Date 2001 SIENNA RM787U REMOVAL 1 REMOVE HEATER CONTROL NAME PLATE Using a screwdriver pull out heater control name plate HINT Tape the screwdriver tip before use 2 REMOVE REAR HEATER CONTROL ASSEMB...

Page 1938: ...knob b Remove the 2 screws and switch 3 Manual A C INSPECT REAR BLOWER SWITCH CONTINUITY Position Circuit Tester connection Specified condition OFF No continuity REAR 1 6 8 Continuity LO 5 6 8 Continu...

Page 1939: ...ty AUTO 5 6 8 Continuity Illumination circuit 9 10 Continuity Illumination circuit If continuity is not as specified check the bulb Switch continuity If continuity is not as specified replace the swit...

Page 1940: ...he connector b Remove the 3 screws and blower motor 6 INSPECT REAR COOLER BLOWER MOTOR OPERA TION Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 then chec...

Page 1941: ...Remove the 2 screws and blower resistor 6 INSPECT BLOWER RESISTOR RESISTANCE Measure resistance between terminals as shown in the chart below Tester connection Condition Specified condition 1 3 Const...

Page 1942: ...in Hose Cooling Unit Case Manual A C Blower Resistor Auto A C Power Transistor Packing Parts Clamp O Ring Liquid Tube 14 140 10 5 4 55 48 in lbf N m kgf cm ft lbf Specified torque Non reusable part Co...

Page 1943: ...Remove the screw and parts clamps b Remove the 2 screws and bracket c Pry out the packings HINT At the time of reassembly please refer to the following item Do not reuse the packing d Remove the hold...

Page 1944: ...UCT Remove the 2 screws 4 holding springs and air duct 9 REMOVE EVAPORATOR a Remove the 10 screws and separate the cooling unit cases b Remove the evaporator HINT At the time of reassembly please refe...

Page 1945: ...Author Date 2001 SIENNA RM787U INSPECTION 1 CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air NOTICE Never use water to clean the evaporator 2 CHECK FITTINGS F...

Page 1946: ...AC0SH 02 AC 40 AIR CONDITIONING REAR COOLING UNIT 1881 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 35...

Page 1947: ...eak detector check for leakage If there is leakage check the tightening torque at the joints or check the evaporator 7 CHECK AMOUNT OF GAS DURING REFRIGERANT CYCLE 8 SET ON MANIFOLD GAUGE SET See page...

Page 1948: ...AC0SG 02 AIR CONDITIONING REAR COOLING UNIT AC 39 1880 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 36...

Page 1949: ...TION TUBES a Remove the bolt and nut Torque 10 N m 100 kgf cm 7 ft lbf b disconnect the both tubes NOTICE Cap the open fittings immediatelty to keep moisture or dirt out of the system HINT At the time...

Page 1950: ...thor Date 2001 SIENNA RM787U REAR RELAY INSPECTION 1 REMOVE REAR NO 2 SEAT 2 REMOVE SLIDE DOOR SCUFF PLATE See page BO 108 3 REMOVE BACK DOOR SCUFF PLATE See page BO 108 4 REMOVE REAR LH QUARTER TRIM...

Page 1951: ...dition Tester connection Specified condition Constant 1 2 3 4 Continuity Apply B between terminals 1 and 2 3 5 Continuity If continuity is not as specified replace the relay 11 INSPECT REAR M1 RELAY C...

Page 1952: ...AC0SV 01 AIR CONDITIONING RECEIVER AC 71 1912 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 70...

Page 1953: ...ING RECEIVER AC 69 1910 Author Date 2001 SIENNA RM787U RECEIVER ON VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage If there is leakage check the tighteneing...

Page 1954: ...ct the both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system HINT At the time of installation please refer to the following...

Page 1955: ...ver Suction Tube 32 330 24 10 100 7 10 100 7 14 140 10 10 100 7 14 140 10 5 4 55 48 in lbf 10 100 7 Compressor Liquid Tube 5 4 55 48 in lbf 10 100 7 Liquid Tube N m kgf cm ft lbf Specified torque AIR...

Page 1956: ...GERANT LINE 1863 Author Date 2001 SIENNA RM787U REFRIGERANT LINE ON VEHICLE INSPECTION 1 INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2 INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detec...

Page 1957: ...denser x Liquid tube 14 140 10 Compressor x Discharge hose 10 100 7 Compressor x Suction hose 10 100 7 Front cooling unit x Liquid tube 5 4 55 48 in lbf Front cooling unit x Suction hose 5 4 55 48 in...

Page 1958: ...Remove the 2 screws and blower resistor 7 INSPECT BLOWER RESISTOR RESISTANCE Measure resistance between terminals as shown in the chart below Tester connection Condition Specified condition 1 3 Const...

Page 1959: ...LATE See page BO 108 3 REMOVE BACK DOOR SCUFF PLATE See page BO 108 4 REMOVE REAR LH QUARTER TRIM PANEL See page BO 108 5 REMOVE REAR HI RELAY a Remove the screw b Remove the rear hi relay from rear c...

Page 1960: ...ECTION 1 REMOVE LOWER FINISH PANEL See page BO 101 2 REMOVE NO 1 SAFETY PAD INSERT See page BO 101 3 REMOVE REAR HEATER RELAY FROM RELAY BLOCK NO 5 4 INSPECT REAR HEATER RELAY CONTINUITY Condition Tes...

Page 1961: ...e Trim Rear Heater Unit Rear Console Box Garnish Scuff Plate Heater Case Manual A C Blower Resistor Auto A C Power Transistor Heater Radiator Blower Motor Heater Case Blower Fan Air Mix Servomotor Aut...

Page 1962: ...REMOVE AIR INLET TEMPERATURE SENSOR Remove the screw and air inlet temperature sensor 4 REMOVE AIR MIX SERVOMOTOR Remove the 2 screws and servomotor 5 REMOVE HEATER RADIATOR a Remove the 2 screw and 2...

Page 1963: ...T FINS FOR BLOCKAGE If the fins are clogged clean them with compressed air 2 INSPECT REAR HEATER BLOWER MOTOR OPERA TION Connect the positive lead from the battery to terminal 1 and the negative lead...

Page 1964: ...AC0SM 02 AIR CONDITIONING REAR HEATER UNIT AC 53 1894 Author Date 2001 SIENNA RM787U INSTALLATION Installation is in the reverse order of removal See page AC 48...

Page 1965: ...AC0SL 02 AC 52 AIR CONDITIONING REAR HEATER UNIT 1893 Author Date 2001 SIENNA RM787U REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 50...

Page 1966: ...clips and slide the hose clips along the hose b Disconnect the water hose HINT At the time of installation please refer to the following item Push the water hose onto the heater radiator pipe as far a...

Page 1967: ...425 I02427 AIR CONDITIONING REAR HEATER UNIT AC 49 1890 Author Date 2001 SIENNA RM787U c Remove the 2 bolts 2 clips and rear air duct d Disconnect the connectors e Remove the 3 bolts and rear heater u...

Page 1968: ...cluster finish panel with connector still connected HINT Tape the screwdriver tip before use 2 REMOVE ROOM TEMPERATURE SENSOR a Disconnect the connector b Release the 2 claws and remove the room tempe...

Page 1969: ...37 Author Date 2001 SIENNA RM787U ROOM TEMPERATURE SENSOR for Rear A C INSPECTION 1 REMOVE ROOM TEMP SENSOR Using a screwdriver remove the room temp sensor then dis connect the connector HINT Tape the...

Page 1970: ...ENNA RM787U SOLAR SENSOR Auto A C INSPECTION 1 REMOVE SOLAR SENSOR Using a screwdriver pull out the sensor then disconnect the connector HINT Tape the screwdriver tip before use 2 INSPECT SOLAR SENSOR...

Page 1971: ...n switch 3 Wire harness AC 57 AC 122 Air inlet control Recirculation mode does not change when turn air flow selector to FOOT DEF or DEF position 1 A C control assembly Air flow selector 2 A C control...

Page 1972: ...er AC 60 AC 17 AC 133 No condenser fan operation High speed 1 ALT Fuse 2 HTR Fuse 3 Fan No 1 relay 4 CDS Fuse 5 Condenser fan motor 6 Fan No 2 relay 7 Pressure switch 8 No 1 Engine coolant temp switch...

Page 1973: ...Heater blower switch 6 Rear blower switch 7 Wire harness AC 51 AC 83 AC 104 AC 85 AC 86 AC 104 AC 106 AC 137 AC 130 No temperature control 1 HTR Fuse 2 Front heater relay 3 A C Fuse 4 Rear A C contro...

Page 1974: ...r of removal See page AC 80 AFTER INSTALLATION ADJUST WATER VALVE CONTROL CABLE a Set the temperature control dial at COOL position b Set the water valve control lever to COOL position and install the...

Page 1975: ...SPECT WATER VALVE OPERATION a Check that warm air is blown out of the ventilator when the water valve lever is moved to WARM posi tion b Check that cool air is blown out of the ventilator when the wat...

Page 1976: ...CT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT At the time of installation please refer to the following item For installing control cable refer to INSTALLATION on page AC 81 3 DISCONNECT WATER HO...

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