VNX - Su Avensis Supplement Chassis Body 2000 rm781 PDF

FOREWORD
This supplement has been prepared to provide information covering general service repairs for the chassis
and body of the TOYOTA AVENSIS/CORONA which underwent changes in July, 2000.
Applicable models:
ZZT220, 221 series

AZT220 series
ST220 series
CDT220 series
For the service specifications and repair procedures of the above model other than those listed in this supplement, refer to the following manuals.
Manual Name
Pub. No.
AVENSIS/CORONA Chassis and Body Repair Manual
RM599E
AVENSIS/CORONA Chassis and Body Repair Manual Supplement (Aug., 1999)
RM698E
1ZZFE, 3ZZFE Engine Repair Manual
RM782E
1AZFSE Engine Repair Manual
RM783E
3SFE Engine Repair Manual
RM395E
3SFE Engine Repair Manual Supplement (Jan., 1996)
RM495E
3SFE Engine Repair Manual Supplement (Oct., 1997)
RM609E
1CDFTV Engine Repair Manual
RM697E
A245E Automatic Transaxle Repair Manual
RM757E
U240E Automatic Transaxle Repair Manual
RM740U
AVENSIS/CORONA Electrical Wiring Diagram
EWD330Y
AVENSIS/CORONA Electrical Wiring Diagram Supplement (May, 1999)
EWD373F
AVENSIS/CORONA Electrical Wiring Diagram Supplement (Jul., 2000)
EWD418F
AVENSIS/CORONA New Car Features
NCF145E
AVENSIS/CORONA New Car Features Supplement
NCF168E
TOYOTA Model New Car Features Supplement
NCF195E
All information in this manual is based on the latest product information at the time of publication. However,
specifications and procedures are subject to change without notice.
TOYOTA MOTOR CORPORATION
2000 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be reproduced or copied, in whole or in part, without the
written permission of Toyota Motor Corporation.
First Printing: May 17, 2000 0100051700
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MANUAL TRANSAXLE (E351)

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE UNIT . . . . . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY . . . . . . . .
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .
MX1
MX2
MX9
MX23
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT AND SELECT LEVER SHAFT . . . . . . .
DIFFERENTIAL CASE . . . . . . . . . . . . . . . . . . . .
SHIFT LEVER AND CONTROL CABLE . . . . .
MX29
MX37
MX38
MX45
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MX1
TROUBLESHOOTING
TROUBLESHOOTING
MX01Z07
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom
Suspect Area
See page
Noise
1. Oil (Level low)

2. Oil (Wrong)
3. Gear (Worn or damaged)
4. Bearing (Worn or damaged)
MX4
MX4
MX9
MX9
Oil leakage
1. Oil (Level too high)

2. Gasket (Damaged)
3. Oil seal (Worn or damaged)
4. ORing (Worn or damaged)
MX4
MX9
MX9
MX9
1. Control cable (Faulty)

2. Synchronizer ring (Worn or damaged)
MX45
MX9
MX23
MX29
MX9
MX23
MX29
Hard to shift or will not shift

3. Shift key spring (Damaged)
Jumps out of gear
1. Locking ball spring (Damaged)

2. Shift fork (Worn)
3. Gear (Worn or damaged)
AVENSIS/CORONA SUP (RM781E)
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MX9
MX9
MX9
MX9
MX2
MANUAL TRANSAXLE UNIT

MX09603
COMPONENTS
VSV Connector for EGR
Air Cleaner Case

Assembly
with Air Hose
Air Flow Meter

Connector
No.1 Air Tube Assembly
25 (255, 18)
Control Cable
Turbo Pressure
Sensor Connector
Clip
Clip
Washer
15 (153, 11)
25 (255, 18)
Starter
39 (400, 29)
Battery
Clutch Release
Cylinder
and Line
Stay
Throttle Full
Switch Connector
12 (120, 9)
Tray
52 (530, 38)
z Gasket
87 (890, 64)
12 (120, 9)
Throttle Control
Motor Connector
21 (214, 15)
4.9 (50, 43 in.lbf)
Engine Left
Mounting Bracket
25 (255, 18)
Intake Air Temperature

Sensor Connector
Nm (kgfcm, ftlbf) : Specified torque
z Nonreusable part
Diesel Throttle Body

with No.2 Air Tube Assembly
25 (255, 18)
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D06619
MX3
64 (650, 47)
RH Drive Shaft
Speed Sensor
Connector
BackUp Light
Switch Connector
z Snap Ring
8.0 (82, 71in.lbf)
Ground Cable
LH Drive
Shaft
20 (204, 15)
216 (2,200, 159)
29 (300, 22)
46 (470, 34)
Lock Nut Cap
64 (650, 47)
z Cotter Pin
98 (1,000, 72)
64 (650, 47)
49 (500, 36)
Tie Rod End

40 (408, 30)
Engine Rear
Mounting Bracket
87 (890, 64)
43 (440, 32)
Transaxle Case
Protector
z Gasket
64 (650, 47)
Engine Front
Mounting Bracket
18 (185, 13)
Engine Front
Mounting
Engine Mounting
Center Member
Suction Pipe
127 (1,300, 94)
z Gasket
Front Exhaust Pipe
64 (650, 47)
Bolt with Spring
73 (740, 54)
40 (408, 30)
52 (540, 38)
62 (630, 46)
Hole Plug
Hole Cover
73 (740, 54)
Hole Plug
39 (400, 29)
Front Transport
Hook
x 10
RH Engine Under Cover

x 10

z Nonreusable part
LH Engine Under Cover
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D06618
MX4

MX09703
REMOVAL
1.
2.
3.
4.
(a)
(b)
(c)
(d)
(a)
(b)
REMOVE BATTERY AND TRAY

REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR
HOSE
REMOVE LH AND RH ENGINE UNDER COVERS
REMOVE NO.1 AIR TUBE ASSEMBLY

Disconnect the No.2 vacuum hose from the EVRV for
EGR.
Disconnect the No.2 vacuum hose from the VSV for EGR.
Disconnect the VSV connector for EGR.
Disconnect the turbo pressure sensor connector and vacuum hose.
D06626
(e)
(f)
5.
D06627
(a)
(b)
(c)
(d)
(e)
(f)
Remove the 2 bolts as shown in the illustration.

Torque: 25 Nm (255 kgfcm, 18 ftlbf)
Disconnect the 2 hose clips, and remove the No.1 air tube
assembly.
REMOVE DIESEL THROTTLE BODY WITH NO.2 AIR
TUBE ASSEMBLY
Disconnect the intake air temperature sensor connector.
Disconnect the throttle control motor connector.
Disconnect the full opener switch connector.
Remove the 3 bolts from the diesel throttle body.
Remove the 2 bolts as shown in the illustration.

Disconnect the 2 hose clips, and remove the diesel
throttle body assembly with the No.2 air tube assembly.
D06628
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MX5
6.
(a)
(b)
(c)
(d)
REMOVE STARTER
Remove the 2 bolts and disconnect the radiator reservoir
from the radiator.
Disconnect the starter connector.
Remove the nut, and disconnect the starter wire.
Remove the 2 bolts and starter.
D06629
7.
(a)
(b)
B
D06639
DISCONNECT CLUTCH RELEASE CYLINDER AND

LINE
Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt A: 12 Nm (120 kgfcm, 9 ftlbf)
Bolt B: 4.9 Nm (50 kgfcm, 43 in.lbf)
Remove the 2 bolts and disconnect the release cylinder
and line.
8.
DISCONNECT GROUND CABLE
Remove the set bolt of the ground cable from the transaxle.
9.
DISCONNECT VEHICLE SPEED SENSOR AND
BACKUP LIGHT SWITCH CONNECTORS
10. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
D06633
11.
A
B
REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING

BOLTS
Torque:
Bolt B: 29 Nm (296 kgfcm, 21 ftlbf)
D06636
12. INSTALL ENGINE SUPPORT FIXTURE

Install the engine hanger in the correct direction.
Parts No.:
Engine hanger: 1228127010
Bolt: 9612261020
D06634
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MX6
13.
REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET

BOLTS AND NUT
Torque:
Nut B: 87 Nm (890 kgfcm, 64 ftlbf)
A
D06632
14. REMOVE ENGINE LEFT MOUNTING BRACKET

Lower the transaxle side and remove the bolt and bracket.
15. REMOVE FRONT WHEEL
Torque: 216 Nm (2,200 kgfcm, 159 ftlbf)
16. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
D06638
Filler Plug
17.
Oil Level
0 5 mm
18.
(a)
Drain Plug
D08920
(b)
19.
20.
(a)
(b)
(c)
DRAIN TRANSAXLE OIL

Oil grade: API GL4 or GL5
Viscosity: SAE 75W90
Capacity: 2.5 liters (2.6 US qts, 2.2 Imp. qts)
REMOVE FRONT EXHAUST PIPE
Remove the 2 bolts, 2 nuts and gasket from the exhaust
manifold.
Remove the 2 bolts, 2 springs, gasket and pipe.
REMOVE LH AND RH FRONT DRIVE SHAFTS
(See page SA1)
REMOVE ENGINE MOUNTING CENTER MEMBER

Remove the 2 bolts and front transport hook.
Support the suspension crossmember with a jack.
Remove the nuts, and disconnect the suction pipe.
D06631
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MX7
(d)
(e)
Remove the 2 hole plugs and hole cover.

Remove the 7 bolts and center member.
Torque:
21. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
A
B
A
D06630
22. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 4 bolts and bracket.
Torque:
Bolt A: 98 Nm (1,000 kgfcm, 72 ftlbf)
A
B
D02167
23.
(a)
(b)
REMOVE ENGINE FRONT MOUNT AND MOUNTING

BRACKET
Remove the bolt and nut.
Remove the 2 bolts.
D06635
24.
A
B
D06637
REMOVE TRANSAXLE LOWER SIDE MOUNTING

BOLT
Remove the 5 bolts.
Torque:
Bolt C: 8.0 Nm (82 kgfcm, 71 in.lbf)
Bolt D: 20 Nm (204 kgfcm, 15 ftlbf)
Bolt E: 46 Nm (470 kgfcm, 34 ftlbf)
25. REMOVE TRANSAXLE
Lower engine left side and remove the transaxle from the engine.
HINT:
At the time of installation, please refer to the following items.
S
Align the input shaft with the clutch disc and install the
transaxle to the engine.
S
Temporarily tighten the transaxle mounting bolts.
26. REMOVE TRANSAXLE CASE PROTECTOR
Remove the 2 bolts and protector.
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MX8

MX05P03
INSTALLATION
Installation is in the reverse order of removal (See page MX4).
HINT:
After installation, check and inspect items as follows.
S
Front wheel alignment (See Pub. No. RM599E on page SA4).
S
Do the road test.
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MX9
MANUAL TRANSAXLE ASSEMBLY

MX09803
COMPONENTS
Clutch Release Assembly
with Bearing
Clutch Release Fork Support
17 (175, 13)
Boot
Speed Sensor
17 (175, 13)
L Straight Screw Plug

25 (250, 18)
Control Cable Bracket
Transaxle Case Receiver

Clutch Tube Bracket
7.4 (75, 65 in.lbf)
17 (175, 13)
Transaxle Case
Magnet
z Output Shaft Cover

z Output Shaft Front
Bearing
z Input Shaft Front
Bearing
z Front Oil Seal
Differential Case Assembly

z Nonreusable part
L Precoated part
D10263
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MX10
Reverse Shift Arm Bracket Assembly
Reverse Shift Fork

No. 1 Shift Fork
24 (240, 17)

25 (250, 18)
No. 1 Shift Fork Shaft

Snap Ring
17 (175, 13)
25 (250, 18)
Interlock Roller
Snap Ring
Snap Ring
No. 3 Shift Fork
13 (130, 9)
z Gasket
Slotted
Spring Pin
z Gasket
25 (250, 18)
Shift Head
24 (240, 17)
24 (240, 17)
No. 2 Shift Fork
BackUp Light Switch

L Straight Screw Plug 40 (410, 30)
Reverse
Restrict Pin
No. 2 Oil
Receiver Pipe
Lock Ball Assembly
20 (200, 14)
29 (300, 22)
Breather Plug z Gasket

49 (500, 36)
L
L
x 17 L 20 (200, 14)
Shift and Select Lever
Shaft Assembly
17 (175, 13)
No. 1 Oil Receiver Pipe
29 (300, 22)
Selecting Bellcrank
Assembly
z Gasket
z Gasket
49 (500, 36)
Filler Plug
Transmission Case
49 (500, 36)
29 (300, 22)
Drain Plug
z Nonreusable part
L Precoated part
x 10
Transmission Case Cover
D10264
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MX11
Input Shaft Assembly

z Output Shaft Rear
Bearing Outer Race
Output Shaft Assembly

Reverse Idler Gear
Shim
Thrust Washer
Reverse Idler
Gear Shaft
L Lock Bolt
29 (300, 22)
42 (430, 31)
x7
Rear Bearing Retainer
Snap Ring
Needle Roller Bearing
Inner Synchronizer
Ring
5th Gear
Key Spring
z Output Shaft
Lock Nut
Middle Synchronizer
Ring
123 (1,250, 90)
Outer Synchronizer Ring
5th Driven Gear

Snap Ring
Synchronizer Pull Ring

Key Spring
No. 3 Clutch Hub
No. 3 Hub Sleeve
z Nonreusable part
L Precoated part
Snap Ring
D09632
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MX12

MX09903
DISASSEMBLY
1.
2.
REMOVE RELEASE FORK AND BEARING

REMOVE BACKUP LIGHT SWITCH WITH GASKET
3.
REMOVE BOLT AND VEHICLE SPEED SENSOR
4.
REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and No.2 selecting bellcrank with the selecting bellcrank support.
Sealant:
Part No. 0883300080, THREE BOND 1344, LOCTITE
242 or equivalent
5.
REMOVE LOCK BALL ASSEMBLY WITH GASKET
6.
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY WITH GASKET
Remove the 4 bolts, the shift, select lever shaft assembly and
gasket.
Sealant:
242 or equivalent
7.
REMOVE TRANSMISSION CASE COVER
Remove the 10 bolts and transmission case cover.
FIPG:
Part No. 0882600090, THREE BOND 1281 or equivalent
8.
REMOVE BREATHER PLUG WITH GASKET
FIPG
Q05816
9.
(a)
(b)
(c)
(d)
10.
(a)
Q00449
(b)
REMOVE OUTPUT SHAFT LOCK NUT

Remove the lock nut.
Engage the gear double meshing.
Disengage the gear double meshing.
REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
Remove the No.3 shift fork set bolt.
Remove the No.3 hub sleeve and No.3 shift fork.
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MX13
11. REMOVE 5TH DRIVEN GEAR

Using SST, remove the 5th driven gear.
SST 0995030011
SST
Q05849
12.
MEASURE 5TH GEAR THRUST CLEARANCE AND

RADIAL CLEARANCE
Using a dial indicator, measure the thrust clearance.
Minimum clearance:
0.10 mm (0.0039 in.)
Maximum clearance:
0.65 mm (0.0256 in.)
(a)
Z01304
(b)
Using a dial indicator, measure the radial clearance.

Maximum clearance:
0.050 mm (0.0020 in.)
REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
Using 2 screwdrivers and a hammer, tap out the snap
ring.
13.
(a)
Z01306
HINT:
At the time of the reassembly, please refer to the following item.
Select a snap ring that allows the minimum axial play.
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
1.75 (0.0689)
2.00 (0.0787)
1.80 (0.0709)
2.05 (0.0807)
1.85 (0.0729)
2.10 (0.0827)
1.90 (0.0748)
2.15 (0.0847)
1.95 (0.0768)
Q00299
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MX14
(b)
SST
Z01308
Using SST, remove the No.3 clutch hub with the synchronizer ring and 5th gear.
SST 0995030011
14. REMOVE NEEDLE ROLLER BEARING AND SPACER
15. REMOVE REAR BEARING RETAINER
Using a torx socket wrench (T45), remove the 7 torx screws and
rear bearing retainer.
Sealant:
242 or equivalent
16.
(a)
(b)
REMOVE SNAP RING

Using a snap ring expander, remove the input shaft rear
bearing snap ring.
Using 2 screwdrivers and a hammer, remove the 2 snap
rings.
Q06190
17. REMOVE STRAIGHT SCREW PLUG

Using a hexagon wrench (6 mm), remove the plug.
Sealant:
242 or equivalent
Q01615
18.
REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT

Sealant:
242 or equivalent
Q00056
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MX15
19. REMOVE TRANSMISSION CASE

Remove the 17 bolts and tap the case with a plastic hammer.
FIPG:
FIPG
D10267
20. REMOVE SHIM

HINT:
At the time of reassembly, please refer to the following item.
Install the previously selected shim by adjusting output shaft
preload.(See page MX21)
MT0669
21.
REMOVE OUTPUT SHAFT REAR TAPER ROLLER

BEARING OUTER RACE
Using SST and a hammer, remove the output shaft rear taper
roller bearing outer race.
SST 0931660011 (0931600011)
SST
MT0693
22.
REMOVE REVERSE SHIFT ARM BRACKET ASSEMBLY

Remove the bolt and pull off the reverse shift arm and bracket.
23. REMOVE REVERSE IDLER GEAR AND SHAFT
Pull out the shaft, remove the reverse idler gear and thrust
washer.
D08951
HINT:
Align the matchmarks, as shown.
Matchmarks
Z17557
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MX16
24. REMOVE STRAIGHT SCREW PLUG

Using a hexagon wrench (6 mm), remove the 2 plugs.
Sealant:
242 or equivalent
D09368
25.
Q08124
REMOVE NO.1, NO.2 SHIFT FORKS AND SHIFT HEAD

SET BOLT
26. REMOVE NO.1 SHIFT FORK SHAFT
Pull up the No.3 shift fork shaft, remove the No.1 shift fork shaft.
HINT:
When it is difficult to push the fork shaft through the reverse shift
fork, pull up the No.3 shift fork shaft.
27. REMOVE INTERLOCK ROLLER
Using a magnetic finger, remove the interlock roller from the reverse shift fork.
Q08125
28.
(a)
(b)
REMOVE NO.2 SHIFT FORK SHAFT, SHIFT HEAD

AND NO.1 SHIFT FORK
Pull out the No.2 shift fork shaft.
Remove the shift head and No.1 shift fork.
Q08126
29.
(a)
(b)
30.
(a)
(b)
Z00182
REMOVE NO.3 SHIFT FORK SHAFT WITH REVERSE

SHIFT FORK AND NO.2 SHIFT FORK
Pull out the No.3 shift fork shaft with the reverse shift fork.
Remove the No.2 shift fork.
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, remove the snap
ring and reverse shift fork from the No.3 shift fork shaft.
Using 2 screwdrivers and a hammer, remove the 3 snap
rings from the No.1, No.2 and No.3 shift fork shafts.
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MX17
31.
(a)
(b)
32.
33.
(a)
MT0781
REMOVE INPUT AND OUTPUT SHAFTS ASSEMBLY

Leaning the output shaft to the differential side, remove
the input shaft assembly.
Lift up the differential case assembly, remove the output
shaft assembly.
REMOVE MAGNET FROM TRANSAXLE CASE
REMOVE NO.5 SYNCHRONIZER RING WITH KEY

SPRING FROM NO.3 CLUTCH HUB
Remove the No.5 synchronizer ring with the key spring
from the No.3 clutch hub.
Using a screwdriver, remove the snap ring.
(b)
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.
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MX18

MX05W03
INSPECTION
1.
(a)
(b)
INSPECT NO.5 SYNCHRONIZER RING

Check for wear or damage.
Check the braking effect of the synchronizer ring. Turn the
middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If it does not lock, replace the synchronizer ring.
MT0782
2.
MEASURE No.3 SHIFT FORK AND HUB SLEEVE

CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 0.35 mm (0.014 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
WM0066
3.
(a)
(b)
SST
(c)
IF NECESSARY, REPLACE INPUT SHAFT BEARING

AND OIL SEAL
Remove the 3 bolts and transaxle case receiver.
Using SST, pull out the bearing.
SST 0961265014
Using a screwdriver, remove the oil seal.
D09369
(d)
SST
(e)
Using SST, drive in a new oil seal.

SST 0960800081, 0995070010 (0995107150)
Coat the lip of seal with MP grease.
Z00194
(f)
SST
(g)
(h)
Using SST, drive in a new bearing.

SST 0995060010 (0995100580), 0995070010
(0995107150)
Install the transaxle case receiver.
Install and torque the 3 bolts.
Torque: 7.4 Nm (75 kgfcm, 65 in.lbf)
D09370
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MX19
(i)
Using SST and a press, remove the inner race.

SST 0995000020
(j)
Using SST and a press, install a new input shaft front

bearing inner race.
SST 0931660011 (0931600021)
4.
IF NECESSARY, REPLACE OUTPUT SHAFT FRONT

BEARING OUTER RACE AND OUTPUT SHAFT
FRONT COVER
Using SST, pull out the output shaft front bearing outer
race.
SST 0930800010
Remove the output shaft cover.
SST
Q05164
SST
Q00141
SST
(a)
(b)
Q00338
(c) Install a new output shaft cover.

HINT:
Install the output shaft cover projection into the case side
groove.
D09371
(d)
SST
Using SST and a hammer, drive in a new output shaft front

bearing outer race.
SST 0931660011 (0931600011, 0931600021)
D09372
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MX20
(e)
Using SST and a socket wrench, remove the output shaft

front bearing.
SST 0995000020, 0995000030
(f)
Using SST and a press, install a new output shaft front

bearing.
SST 0931660011 (0931600071)
5.
(a)
(b)
IF NECESSARY, REPLACE REVERSE RESTRICT PIN

Using a hexagon wrench (6 mm), remove the screw plug.
Using a pin punch and hammer, drive out the slotted
spring pin.
Replace the reverse restrict pin.
Socket Wrench
SST
Q00245
SST
Z00199
(c)
Q01611
(d)
(e)
(f)
Z00201
Using a pin punch and hammer, drive in the slotted spring

pin.
Apply sealant to the screw plug threads.
Sealant:
242 or equivalent
Using a hexagon wrench (6 mm), install and torque the
screw plug.
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MX21

MX05X04
REASSEMBLY
Reassembly is in the reverse order of disassembly.
(See page MX12)
NOTICE:
When working with FIPG material, you must observe the following items.
S
Using a razor blade and gasket scraper, remove all the old
FIPG material from the gasket surfaces.
S
Thoroughly clean all components to remove all the loose
material.
S
Clean both sealing surfaces with a nonresidue solvent.
S
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along
the sealing surface.
S
Parts must be assembled within 10 minutes of application.
Otherwise, the FIPG material must be removed and reapplied.
HINT:
S
Before reassembly, select a shim by adjusting output

shaft preload.
S
Coat all of the sliding and rotating surfaces with gear oil
before reassembly.
ADJUST OUTPUT SHAFT PRELOAD
(a) Install the output shaft assembly to the transaxle case.
(b) Install the transmission case to the transaxle case.
HINT:
If necessary, tap on the case with a plastic hammer.
(c) Install and torque the 17 bolts.
(d) Install the output shaft rear taper roller bearing outer race.
(e) Install the adjusting shim.
HINT:
When reusing the output shaft bearing, first install a shim of the
same thickness as before. If installing a new taper roller bearing, first select and install a shim of lesser thickness than before.
(f)
Install the rear bearing retainer.
(g) Using a torx wrench (T45), install and torque the 7 torx
screws.
(h) Install a new lock nut to the output shaft.
(i)
Turn the output shaft right and left 2 or 3 times to allow the
bearing to settle.
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MX22
(j)
Using a torque wrench, measure the preload.

Preload (at starting):
New bearing
0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf)
Reused bearing
0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
If the preload is not within the specification, select an appropriate adjusting shim.
Z12593
(k)
(l)
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
1.30 (0.0512)
1.95 (0.0768)
1.35 (0.0531)
2.00 (0.0787)
1.40 (0.0551)
2.05 (0.0807)
1.45 (0.0571)
2.10 (0.0827)
1.50 (0.0591)
2.15 (0.0846)
1.55 (0.0610)
2.20 (0.0866)
1.60 (0.0630)
2.25 (0.0886)
1.65 (0.0650)
2.30 (0.0906)
1.70 (0.0669)
2.35 (0.0925)
1.75 (0.0689)
2.40 (0.0945)
1.80 (0.0709)
2.45 (0.0965)
1.85 (0.0728)
2.50 (0.0984)
1.90 (0.0748)

Remove these parts. Removal is in the reverse order of
installation.
S
Rear bearing retainer
S
Shim
S
Transmission case
S
Output shaft assembly
S
Output shaft rear bearing outer race
http://vnx.su
MX23
INPUT SHAFT
INPUT SHAFT
MX02806
COMPONENTS
Spacer
Synchronizer Ring
4th Gear
Snap Ring
Needle Roller
Bearing
3rd Gear
Rear Bearing
Spring
Snap Ring
Synchronizer Ring
Input Shaft
No. 2 Hub Sleeve

No. 2 Clutch Hub
Shifting Key
z Input Shaft Front Bearing Inner Race
z Nonreusable part
D08963
http://vnx.su
MX24
INPUT SHAFT
MX02904
DISASSEMBLY
1.
3rd Gear
4th Gear
Q06369
Q00111
SST
MEASURE 3RD AND 4TH GEARS THRUST CLEARANCE

Using a feeler gauge, measure the thrust clearance.
Minimum clearance:
3rd gear and 4th gear: 0.10 mm (0.0039 in.)
Maximum clearance:
3rd gear: 0.40 mm (0.0157 in.)
4th gear: 0.60 mm (0.0236 in.)
2.
CHECK 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Maximum clearance:
3rd gear: 0.053 mm (0.0021 in.)
4th gear: 0.051 mm (0.0020 in)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3.
REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
4.
REMOVE REAR BALL BEARING AND 4TH GEAR
Using SST and a press, remove the rear bearing.
SST 0995000020
5.
REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6.
REMOVE SNAP RING
Q05165
7.
REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRONIZER RING AND 3RD GEAR
Using a press, remove the No.2 hub sleeve, 3rd gear and synchronizer rings.
8.
REMOVE NEEDLE ROLLER BEARING
Q00115
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MX25
INPUT SHAFT
MX02A04
INSPECTION
1.
(a)
(b)
INSPECT 3RD GEAR SYNCHRONIZER RING

synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
MT0780
(c)
Using a feeler gauge, measure the clearance between

the synchronizer ring back and gear spline end.
Minimum clearance: 0.65 mm (0.026 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
WM0065
2.
(a)
(b)
WM0064
INSPECT 4TH GEAR SYNCHRONIZER RING

If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d)
WM0065

the synchronizer ring back and spline end.
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.
NOTICE:
off after rubbing.
http://vnx.su
MX26
INPUT SHAFT
3.
MEASURE NO.2 SHIFT FORK AND HUB SLEEVE

CLEARANCE
hub sleeve.
WM0066
4.
(a)
(b)
INSPECT INPUT SHAFT

Check the input shaft for wear or damage.
Using a micrometer, measure the outer diameter of the input shaft journal surface.
Minimum outer diameter:
Part A: 27.957 mm (1.1007 in.)
Part B: 35.984 mm (1.4167 in.)
(c)
Using a dial indicator, check the shaft runout.

Maximum runout: 0.03 mm (0.0012 in.)
Z19371
Q00173
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MX27
INPUT SHAFT
MX0D201
REASSEMBLY
Press
D09373
SST
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1.
INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to front of the
transmission.
2.
INSTALL NEEDLE ROLLER BEARING, 3RD GEAR,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Assemble the needle roller bearings into the 3rd gear.
(c) Place the synchronizer rings on the gear and align the
ring slots with the shifting keys.
(d)
Using SST and a press, install the 3rd gear and No.2 hub
sleeve.
SST 0950635010
3.
(a)
INSTALL SNAP RING

D09374
Q00116
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.30 (0.0906)
2.50 (0.0984)
2.35 (0.0925)
2.55 (0.1004)
2.40 (0.0945)
2.60 (0.1024)
2.45 (0.0965)
(b)
4.
Using a screwdriver and hammer, tap in the snap ring.

MEASURE 3RD GEAR THRUST CLEARANCE
(See page MX24)
http://vnx.su
MX28
5.
N00494
(d)
(e)
6.
(a)
Q00118
INPUT SHAFT
INSTALL SPACER, SYNCHRONIZER RING, NEEDLE

ROLLER BEARING, 4TH GEAR AND REAR BALL
BEARING
Install the spacer.
Apply MP grease to the needle roller bearings.
Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
Install the 4th gear.
Using SST and a press, install the rear ball bearing.
SST 0950635010
INSTALL SNAP RING
(a)
(b)
(c)
SST
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.35 (0.0925)
2.55 (0.1004)
2.40 (0.0945)
2.60 (0.1024)
2.45 (0.0965)
2.65 (0.1043)
2.50 (0.0984)
2.70 (0.1063)
(b)
7.

MEASURE 4TH GEAR THRUST CLEARANCE
(See page MX24)
http://vnx.su
MX29
OUTPUT SHAFT
OUTPUT SHAFT
MX02C06
COMPONENTS
3rd Driven Gear
4th Driven Gear
Spacer
1st Gear Bearing Inner Race
Inner Race
2nd Gear
Spacer
No.1 Hub Sleeve
z Output Shaft
Rear Bearing
Needle Roller
Bearing
Spring
1st Gear
Synchronizer Ring
No.1 Clutch Hub
Ball
Shifting Key
z Output Shaft Front
Bearing
Synchronizer Ring
Output Shaft
z Nonreusable part
D08964
http://vnx.su
MX30
OUTPUT SHAFT
MX02D05
DISASSEMBLY
1.
1st Gear
2nd Gear
Q06370
MEASURE 1ST AND 2ND GEARS THRUST CLEARANCE

Minimum clearance:
1st gear: 0.25 mm (0.0098 0.0138 in.)
2nd gear: 0.10 0.45 mm (0.0039 0.0177 in.)
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.35 mm (0.0137 in.)
2.
CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
the gear and shaft.
Maximum clearance:
1st and 2nd gears: 0.053 mm (0.0020 in.)
Z00218
3.
(a)
(b)
REMOVE OUTPUT SHAFT REAR BEARING, 4TH

DRIVEN GEAR AND SPACER
Using a press, remove the bearing and 4th driven gear.
Remove the spacer.
Z00219
4.
REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5.
REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6.
REMOVE INNER RACE AND BALL FROM OUTPUT
SHAFT
Z00220
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MX31
OUTPUT SHAFT
7.
REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST

GEAR
Using a press, remove the No.1 hub sleeve and 1st gear.
8.
REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING
Z00222
9.
REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 0995000020
SST
Q06202
10. REMOVE OUTPUT SHAFT FRONT BEARING

Using SST, remove the output shaft front bearing.
SST 0995000020, 0995000030
SST
Q00296
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MX32
OUTPUT SHAFT
MX02E04
INSPECTION
1.
(a)
(b)
D09375
INSPECT 1ST GEAR SYNCHRONIZER RING

NOTICE:
off after rubbing.
(d)
D09376

NOTICE:
off after rubbing.
2.
(a)
(b)
INSPECT 2ND GEAR SYNCHRONIZER RING

Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
MT0780
(c)

MT0787
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MX33
OUTPUT SHAFT
3.
MEASURE NO.1 SHIFT FORK AND HUB SLEEVE

CLEARANCE
hub sleeve.
WM0066
AA
4.
(a)
(b)
INSPECT OUTPUT SHAFT

Check the output shaft for wear or damage.
Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Part A: 37.610 mm (1.4807 in.)
Part B: 34.502 mm (1.3584 in.)
(c)

Q06203
Q06191
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MX34
OUTPUT SHAFT
MX02F07
REASSEMBLY
HINT:
reassembly.
1.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
Front
Q06204
Align the holes
2.
INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 0950635010
HINT:
Align the hole of the output shaft and inner race.
SST
Q06205
3.
(a)
(b)
(c)
INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,

SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
Apply MP grease to the needle roller bearing.
Install the 1st gear.
Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
D08965
(d)
4.
Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 0931660011 (0931600041)
MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX30)
SST
Q06206
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MX35
OUTPUT SHAFT
5.
INSTALL BALL AND INNER RACE TO OUTPUT SHAFT
HINT:
Align the groove of the inner race and ball.
Q06314
6.
D09377
INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
7.
MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX30)
N00495
8.
(a)
(b)
INSTALL SPACER AND 4TH DRIVEN GEAR

Install the spacer.
Using a press, install the 4th driven gear.
Z00390
9.
INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 0950630012
SST
Z00391
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MX36
OUTPUT SHAFT
10. INSTALL OUTPUT SHAFT FRONT BEARING

Using SST and a press, install a new output shaft front bearing.
SST 0931660011 (0931600071)
SST
Z00392
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MX37
SHIFT AND SELECT LEVER SHAFT

MX02I06
COMPONENTS
Control Shaft Cover
z Oil Seal Dust Boot
Shift Interlock Plate
Transmission Oil Baffle
No. 1 Compression Spring
Snap Ring
No. 1 Select Spring Seat
Slotted Spring Pin
No. 2 Shift Inner Lever
No. 2 Compression Spring
Snap Ring
Slotted Spring Pin

Shift and Select Lever Shaft
z Nonreusable part
Apply MP grease
D10265
http://vnx.su
MX38
DIFFERENTIAL CASE
DIFFERENTIAL CASE
MX06004
COMPONENTS
Pinion Thrust Washer
z Oil Seal
Pinion Gear
Straight Pin
Pinion Shaft
Side Gear
z Tapered Roller Bearing
and Outer Race
Side Gear Thrust

Washer
x16
106 (1,080, 78)
Oil Baffle
Diferential
Case
Speed Sensor
Drive Gear
Ring Gear
z Tapered Roller Bearing and Outer Race
Shim
z Oil Seal

z Nonreusable part
D10266
http://vnx.su
MX39
DIFFERENTIAL CASE
MX09A03
DISASSEMBLY
1.
SST
(a)
SST
Matchmarks
D08953
HINT:
Set the claw of SST to the bearing inner race securely.
(b) Remove the speed sensor drive gear.
2.
(a)
(b)
(c)
x16
Speed sensor drive gear side:

REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
Using SST, remove the tapered roller bearing.
SST 0995000020, 0995000030, 0995040011
(0995704010), 0995060010 (0995100530)
REMOVE RING GEAR

Place matchmarks on the ring gear and differential case.
Remove the 16 bolts.
Using a copper hammer, tap on the ring gear to remove
it from the differential case.
D08954
3.
SST
SST
Q04969
Ring gear side:

REMOVE TAPERED ROLLER BEARING FROM DIFFERENTIAL CASE
Using SST, remove the tapered roller bearing.
SST 0995000020, 0995000030, 0995040011
(0995704010), 0995060010 (0995100450)
HINT:
Set the claw of SST to the bearing inner race at the position
where the differential case is indented.
4.
INSPECT SIDE GEAR BACKLASH
Using a dial indicator, measure the backlash of one side gear
while holding one pinion toward the differential case.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
If the backlash is not within the specification, install the correct
thrust washer to the side gears.
Q00807
http://vnx.su
MX40
SST
DIFFERENTIAL CASE
5.
(a)
(b)
(c)
DISASSEMBLE DIFFERENTIAL CASE

Using a pin punch and hammer, drive out the straight pin.
Remove the pinion shaft from the differential case.
Remove the 2 pinions and side gears with the 4 thrust
washers from each gear.
6.
Transmission Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
Using a screwdriver and a hammer, remove the oil seal.
Using a brass bar and hammer, drive out the tapered roller bearing outer race lightly and evenly.
Remove the shim.
Install the shim.
(a)
(b)
D09378
(c)
(d)
HINT:
First select and install a shim of lesser thickness than before.
(e) Using SST and a press, install a new tapered roller bearing outer race.
SST 0931660011 (0931600011, 0931600041)
NOTICE:
When replacing the tapered roller bearing outer race, replace the tapered roller bearing along with it.
D09379
(f)
SST
(g)
Using SST and a hammer, drive in a new oil seal.

SST 0931660010 (0931600011, 0931600031)
Drive in depth: 3.5 0.5 mm (0.138 0.020 in.)
Coat the lip of oil seal with MP grease.
3.5 0.5 mm
D08955
7.
(a)
SST
(b)
(c)
Transaxle Case Side:

IF NECESSARY, REPLACE OIL SEAL AND TAPERED
ROLLER BEARING OUTER RACE
Using a screwdriver and hammer, drive out the oil seal
from the transaxle case.
Using SST, remove the tapered roller bearing outer race.
SST 0931660011 (0931600011, 0931600021)
Remove the oil baffle.
D08956
http://vnx.su
MX41
DIFFERENTIAL CASE
(d) Install the oil baffle.

HINT:
Install the oil baffle projection into the case side cutout.
(e)
Using SST and a press, install a new tapered roller bearing outer race.
SST 0995060020 (0995100890), 0995070010
(0995100150)
(f)

SST 0931660011 (0931600011, 0931600041)
Drive in depth: 0 0.5 mm (0 0.020 in.)
Coat the oil seal lip with MP grease.
SST
D08957
(g)
SST
D08958
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MX42
DIFFERENTIAL CASE
MX09B03
REASSEMBLY
HINT:
reassembly.
1.
(a)
D06021
(b)
(c)
ASSEMBLE DIFFERENTIAL CASE

Install the correct thrust washers and side gears.
Refer to the table below, select thrust washers which will
ensure that the backlash is within the specification. Try to
select washers of the same size for both sides.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
Thickness mm (in.)
Thickness mm (in.)
1.00 (0.0394)
1.20 (0.0472)
1.10 (0.0433)
1.30 (0.0512)
Install the thrust washers and side gears in the differential

case.
Install the pinion shaft.
(d)
Q00807
Using a dial indicator, check the side gear backlash.

Measure the side gear backlash while holding one pinion
toward the differential case.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
If the backlash is not within the specification, install a thrust
washer of different thickness.
(e) Using a pin punch and hammer, drive in the straight pin
through the differential case and hole in the pinion shaft.
(f)
Using a chisel and hammer, caulk the pin holes around
the circumference of the differential case.
http://vnx.su
MX43
Case Side
D08961
2.
(a)
(b)
(c)
(d)
DIFFERENTIAL CASE
INSTALL RING GEAR ON DIFFERENTIAL CASE

Clean the contact surface of the differential case.
Heat the ring gear in boiling water.
Carefully take the ring gear out of the water.
After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential case and contact the
ring gear.
(e) Temporarily install the 16 set bolts.
CAUTION:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(f)
After the ring gear has cooled sufficiently, torque the ring
gear set bolts uniformly at a time.
3.
SST
D08959
Ring gear side:

INSTALL TAPERED ROLLER BEARING
Using SST and a press, install a new tapered roller bearing.
SST 0931660011 (0931600011)
NOTICE:
HINT:
Set SST to the bearing inner race securely.
4.
Speed sensor drive gear side:

INSTALL TAPERED ROLLER BEARING
(a) Place the speed sensor drive gear in position to stop it
turning, and install the speed sensor drive gear.
NOTICE:
Be sure to install the speed sensor drive gear in the correct
direction, as shown in the illustration.
Case Side
D08960
(b)
Using SST, a steel plate and press, install a new tapered

roller bearing.
SST 0931620011, 0931660011 (0931600011)
NOTICE:
HINT:
Set SST to the bearing inner race securely.
SST
D08962
http://vnx.su
MX44
DIFFERENTIAL CASE
5.
CM0061
SST
D09380
INSPECT DIFFERENTIAL TAPERED ROLLER BEARING PRELOAD

NOTICE:
Perform this only when replacing the tapered roller bearing
and outer race of the differential case.
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case to the transaxle case with
the 17 bolts.
(c) Using SST and a torque wrench, turn the differential case
assembly right and left 2 or 3 times to allow the bearings
to settle.
SST 0956432011
(d) Using SST and a torque wrench, measure the preload.
SST 0956432011
New bearing
0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf)
Reused bearing
0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
If the preload is not within the specification, remove the transmission case side outer race of the tapered roller bearing with
SST (See page MX39). Select an appropriate shim.
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.00 (0.0787)
2.45 (0.0965)
2.05 (0.0807)
2.50 (0.0984)
2.10 (0.0827)
2.55 (0.1004)
2.15 (0.0846)
2.60 (0.1024)
2.20 (0.0866)
2.65 (0.1043)
2.25 (0.0886)
2.70 (0.1063)
2.30 (0.0906)
2.75 (0.1083)
2.35 (0.0925)
2.80 (0.1102)
2.40 (0.0945)
2.85 (0.1122)
(e)
(f)
Remove the 17 bolts and transmission case.

Remove the differential case assembly.
http://vnx.su
MX45
SHIFT LEVER AND CONTROL CABLE

MX09C02
COMPONENTS
Air Flow Meter
Connector
Air Cleaner Case

Assembly
with Air Hose
D06624
Console Box Assembly

Shift Lever Knob
Parking Brake Cover
Front Ash Receptacle
Shift Lever Assembly
Cap
12 (120, 9)
Clip
Cap
Air Duct
Transmission Control Cable Bracket
4.9 (50, 43 in.lbf)
Shift Control Cable

Clip
Clip
Clip
Washer
Select Control Cable
Shift Cable Grommet
Shift Cable Grommet
Retainer
Washer
Clip
Washer
4.9 (50, 43 in.lbf)

D06625
http://vnx.su
http://vnx.su
MANUAL TRANSAXLE (S54, S55)

INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .
MX1
MX2
MX8
MX19
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .
MX27
MX34
MX35
MX42
http://vnx.su
http://vnx.su
MX1
TROUBLESHOOTING
TROUBLESHOOTING
MX03004

cause of the problem. Check each part in order. If necessary, replace parts.
Symptom
Suspect Area
See page
Noise
1. Oil (Level low)

2. Oil (Wrong)
3. Gear (Worn
(
or damaged)
g )
MX3
MX3
MX
3
MX8
MX8
Oil leakage

2. Gasket (Damaged)
3. Oil seal ((Worn or damaged)
g )
4. Oring (Worn or damaged)
MX3
MX8
MX
8
MX8
MX8

MX42
MX8
MX19
MX27
MX8
MX19
MX27

3 Shift key spring (Damaged)
3.
Jumps out of gear
1. Locking ball spring

s ring (Damaged)
3. Gear (Worn
(
or damaged)
g )
http://vnx.su
MX8
MX8
MX
8
MX8
MX8
MX2

MX06M02
COMPONENTS
Air Cleaner Case Assembly with Air Hose
RH Drive Shaft
Battery
64 (650, 47)
Tray
64 (650, 47)
BackUp Light Switch Connector

Speed Sensor Connector
Engine Rear Mounting
Bracket
44 (450, 33)
87 (890, 64)
Intake Manifold Stay
64 (650, 47)
Stiffener Plate
21 (210, 15)
64 (650, 47)
Ground Cable
52 (530, 38)
Clip
25 (250, 18)
87 (890, 64)
Washer
43 (440, 32)
Control Cable
43 (440, 32)
Transaxle
z Snap
12 (120, 9)
Clutch Release Cylinder
Ring
Engine Left
Mounting Bracket
LH Drive Shaft
64 (650, 47)
216 (2,200, 159)
Starter
Lock Nut Cap

zCotter Pin
z Gasket
43 (430, 32)
49 (500, 36)
39 (400, 29)
4.9 (50, 43 in.lbf)

12 (120, 9)
Tie Rod End

127 (1,300, 94)
43 (430, 32)
Spring
Front Exhaust Pipe
73 (740, 54)
Hole Plug
62 (630, 46)
72 (740, 53)
Hole Cover
Hole Plug
Front Transport Hook

73 (740, 54)

z Nonreusable part
Engine Mounting
Center Member
39 (400, 29)

D09355
http://vnx.su
MX3

MX06N02
REMOVAL
Starter Set Bolt
1.
REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
2.
(a)
(b)
REMOVE STARTER
Disconnect the connector and wire from the starter.
Remove the 2 bolts and starter.
3.

LINE
Remove the 2 set bolts of the clutch line bracket.
Torque:
Bolt B: 4.9 Nm (50 kgfcm, 43 in.lbf)
Remove the 2 bolts and disconnect the clutch release cylinder and line.
D02128
(a)
(b)
B
D02129
4.
Remove the set bolt of the ground cable from the transaxle.
5.
DISCONNECT CONTROL CABLE
(c) Disconnect the 2 control cables from the transaxle.
6.
DISCONNECT BACKUP LIGHT SWITCH AND SPEED
SENSOR CONNECTORS
D02130
7.

BOLTS
D02131
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MX4
8.
INSTALL ENGINE SUPPORT FIXTURE
9.
REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET

BOLTS AND NUT
Torque:
Nut B: 87 Nm (890 kgfcm, 64 ftlbf)
D02132
A
D02133
D02134

Lower the transaxle side and remove the bolt and bracket.
12. RAISE VEHICLE
NOTICE:
13. REMOVE LH AND RH ENGINE UNDER COVERS
14.
Filler Plug
15.
Oil Level
05 mm
Drain Plug
DRAIN TRANSAXLE OIL

Capacity: 2.2 liters (2.3 US qts, 1.9 lmp. qts)
REMOVE LH AND RH DRIVE SHAFTS
(See page SA3)
D02135
16.
(a)
(b)
REMOVE FRONT EXHAUST PIPE

Remove the 2 bolts, springs and gasket from the exhaust
manifold.
Remove the 2 bolts, nuts, gasket and front exhaust pipe.
D02136
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MX5
17.
(a)
(b)

Support the suspension crossmember with a jack.
D02165
(c)
(d)

Torque:
A
B
A
D02137

Remove the 4 bolts and bracket.
Torque:
A
B
D02138
20. REMOVE INTAKE MANIFOLD STAY

Remove the bolt, nut and intake manifold stay.
D02139
21.
(a)
(b)
B
REMOVE STIFFENER PLATE AND TRANSAXLE LOWER SIDE MOUNTING BOLT

Remove the 6 bolts and stiffener plate.
Torque:
Remove the bolt of transaxle lower side.
D02140
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MX6

Lower engine left side and remove the transaxle from the engine.
HINT:
S
S
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MX7

MX06O02
INSTALLATION
HINT:
S
S
Do the road test.
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MX8

MX03404
COMPONENTS
Release Bearing
Retainer
13 (130, 9)
5.4 (55, 48 in.lbf)

Assembly
Speed Sensor L Lock Ball

Assembly
Reverse
29 (300, 22)
Restrict Pin
37 (375, 27)
37 (380, 27)
BackUp
Light Switch
7.4 (75, 65 in.lbf)
Selecting Bellcrank
44 (450, 33)
Slotted
Spring Pin
Shim
z ORing
Differential Side
Bearing Retainer
Transmission
Case Protector
x6
Release
Bearing
Transmission
Case
Boot
18 (185, 13)
18 (185, 13)
Drain Plug
49 (500, 36)
Release Fork
Clutch Release
Fork Support
z Gasket
z Gasket
47 (480, 35)
Filler Plug
29 (300, 22)
Spacer
z Lock Nut
29 (300, 22)
Lock Bolt
42 (430, 31)
x5
x 17
49 (500, 36)
123 (1,250, 90)
z Gasket
Snap Ring
5th Driven Gear
5th Gear
No.3 Clutch Hub Assembly
No.3 Hub Sleeve
No.3 Shift Fork
18 (185, 13)
Transmission Case Cover
Snap Ring
x8
z Nonreusable Part
L Precoated Part
29 (300, 22)
D02449
http://vnx.su
MX9
Reverse Shift Fork

Interlock Pin
Transaxle Case
z Oil Seal
No.1 Shift Fork
No.2 Shift Fork Shaft

No.2 Shift Fork
Transaxle Case
Receiver
7.4 (75, 65 in.lbf)
No.1 Shift Head

z Input Shaft Front Bearing
Bearing Lock Plate
Input Shaft Assembly

Reverse Shift Arm
18 (185, 13)
Reverse Idler Gear

and Shaft
z Output Shaft Front Bearing

Output Shaft Cover

z Nonreusable Part
Z18962
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MX10

MX03504
DISASSEMBLY
1.
2.

REMOVE BACKUP LIGHT SWITCH
3.
REMOVE BOLT AND SPEED SENSOR
4.
REMOVE RELEASE BEARING RETAINER
Remove the 3 bolts and retainer.
5.
REMOVE SELECTING BELLCRANK
Remove the 2 bolts and selecting bellcrank.
6.
(a)
(b)
FIPG
Z18142
7.
REMOVE TRANSMISSION CASE COVER

Remove the 8 bolts.
Sealant:
Part No.0883300080, THREE BOND 1344, LOCTITE
242 or equivalent
Using a plastic hammer, tap the transmission case cover
and remove it.
FIPG:
REMOVE LOCK BALL ASSEMBLY
Sealant:
242 or equivalent
REMOVE SHIFT AND SELECT LEVER ASSEMBLY
8.
HINT:
Apply FIPG to the underside of the flanged portion of the control
shaft cover.
FIPG:
http://vnx.su
MX11
9.
(a)
(b)
REMOVE OUTPUT SHAFT LOCK NUT

Unstake the nut.
Engage the gear to the double meshing, with the gear into
1st and 3rd or 2nd and 4th.
(c)
Remove the lock nut clockwise and remove it.

Q02530
Install
Remove
Q05696
HINT:
The lock nut has LH threads.
(d) Disengage the double meshing of the gear.
10. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK
(a) Remove the No.3 shift fork set bolt.
(b) Remove the No.3 hub sleeve and No.3 shift fork.
SST 0995040011
SST
Q05200
HINT:
At the time of installation, please refer to the following item.
Using SST, install the 5th driven gear.
SST 0930912020
SST
SST
Z00455
12. MEASURE 5TH GEAR THRUST CLEARANCE

Maximum clearance:
0.57 mm (0.0224 in.)
Minimum clearance:
0.10 mm (0.0039 in.)
Q02695
http://vnx.su
MX12
Q02696
13. MEASURE 5TH GEAR RADIAL CLEARANCE

Maximum clearance:
0.048 mm (0.0019 in.)
Minimum clearance:
0.009 mm (0.0004 in.)
needle roller bearing or input shaft.
14. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
13
2.202.25
(0.08660.0886)
21
2.602.65
(0.10240.1043)
14
2.252.30
(0.08860.0906)
22
2.652.70
(0.10430.1063)
15
2.302.35
(0.09060.0925)
23
2.702.75
(0.10630.1083)
16
2.352.40
(0.09250.0945)
24
2.752.80
(0.10830.1102)
17
2.402.45
(0.09450.0965)
25
2.802.85
(0.11020.1122)
18
2.452.50
(0.09650.0984)
26
2.852.90
(0.11220.1142)
19
2.502.55
(0.09840.1004)
27
2.902.95
(0.11420.1161)
20
2.552.60
(0.10040.1024)
(b)
Using SST and a socket wrench, remove the No.3 clutch

hub with the synchronizer ring.
SST 0995030011
SST
Socket Wrench
Q02726
http://vnx.su
MX13
HINT:
Using SST and a press, install the No.3 clutch hub assembly.
SST 0961222011
(c) Remove the 5th gear.
15. REMOVE NEEDLE ROLLER BEARING
SST
Q02682
x5
Q05785
19.
REMOVE DIFFERENTIAL SIDE BEARING RETAINER

AND SHIM
Remove the 6 bolts, retainer and shim.
Sealant:
242 or equivalent
x 17
x6

Sealant:
Part No.0883300070, THREE BOND 1324 or equivalent
17. REMOVE SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.
18. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
AND GASKET
Q05826
20.
(a)
(b)
FIPG
REMOVE TRANSMISSION CASE

Using a plastic hammer, tap the transmission case and remove it.
FIPG:
Q09474
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MX14
21.
(a)
(b)
22.
(a)
(b)
23.
Q05827
24.
25.
26.
(a)
(b)
(c)
27.
(a)
(b)
(c)
Q03065
(d)
REMOVE REVERSE IDLER GEAR AND SHAFT

Pull out the shaft.
Remove the idler gear and thrust washer.
REMOVE REVERSE SHIFT ARM
Shift the fork shaft into reverse.
Remove the 2 bolts and pull off the reverse shift arm.
REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT
HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE
SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY
REMOVE DIFFERENTIAL CASE ASSEMBLY
REMOVE MAGNET FROM TRANSAXLE CASE
REMOVE NO.2 FORK SHAFT
Using a hexagon wrench, remove the straight screw plug.
Sealant:
242 or equivalent
spring pin.
Pull out the shaft.
SEPARATE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT

HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE
SHIFT FORK
Mount the shift forks to the vise.
spring pin from the No.1 fork shaft.
spring pin from the No.1 fork shaft, as shown in the illustration.
Separate the No.1 shift fork shaft, No.1 shift head, No.1
and No.2 shift forks and reverse shift fork.
http://vnx.su
MX15
28.
(a)
MT0781
REMOVE NO.5 SYNCHRONIZER RING WITH KEY

Remove the No.5 synchronizer ring with the key spring
(b)
HINT:
Wrap vinyl tape on the screwdriver to prevent damaging the
synchronizer ring.
(c) Remove the synchronizer rings.
http://vnx.su
MX16

MX06P02
INSPECTION
1.
(a)
(b)
INSPECT NO.5 SYNCHRONIZER RING

Check wear or damage.
Check the braking effect of the synchronizer ring turn the
middle No.5 synchronizer ring in one direction while pushing it to the outer No.5 synchronizer ring. Check that the
ring locks.
If the braking effect is insufficient, replace the synchronizer ring.
MT0782
2.
INSPECT NO.3 SHIFT FORK AND NO.3 HUB SLEEVE

CLEARANCE
hub sleeve.
WM0066
3.
SST
SST
(a)
(b)
IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING
Remove the 2 bolts and transaxle case receiver.
SST 0930800010
Z00409
(c)
SST
SST
(d)
Using SST and a press in a new bearing.

SST 0931035010
Install the transaxle case receiver and torque the 2 bolts.
Z00410
4.
SST
SST
(a)
(b)

BEARING
Remove the bolt and bearing lock plate.
SST 0930800010
Z00411
http://vnx.su
MX17
(c)
SST
(d)
SST
Using SST and a press in a new bearing.

SST 0931035010
Install the bearing lock plate and torque the bolt.
Front
Z00593
5.
0 0.5 mm
(a)
(b)
SST
(c)
IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL
Using a screwdriver, pry out the oil seal.
SST 0960800081, 0995070010 (0995107150)
Drive in depth: 00.5 mm (00.020 in.)
Coat the lip of the oil seal with MP grease.
Z00413
6.
(a)
(b)
13.5 0.5 mm
Z00596
(c)
(d)
(e)
(f)

spring pin.
pin.
Drive in depth: 13.50.5 mm (0.5310.020 in.)
Apply sealant to the plug threads.
Sealant:
242 or equivalent
Using a hexagon wrench, install and torque the straight
screw plug.
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MX18

MX03704
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MX10).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before assembly.
NOTICE:
S
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
S
Thoroughly clean all components to remove all the loose material.
S
S
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
S
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.
http://vnx.su
MX19
INPUT SHAFT
INPUT SHAFT
MX03804
COMPONENTS
Spacer
4th Gear
Rear Bearing
Snap Ring
Synchronizer Ring
Synchronizer Ring
Shifting Key
Input Shaft
Snap Ring
3rd Gear
No.2 Hub Sleeve
Shifting Key Spring
Q02560
http://vnx.su
MX20
INPUT SHAFT
MX03904
DISASSEMBLY
1.
3rd Gear
4th Gear
Q05793
INSPECT 3RD AND 4TH GEARS THRUST CLEARANCES

Using a feeler gauge, measure each thrust clearance.
Maximum clearance:
3rd gear: 0.35 mm (0.0138 in.)
4th gear: 0.45 mm (0.0177 in.)
Minimum clearance:
3rd gear: 0.10 mm (0.0039 in.)
4th gear: 0.10 mm (0.0039 in.)
2.
Z00417
INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCES

the gear and shaft.
Maximum clearance:
0.051 mm (0.0020 in.)
Minimum clearance:
0.009 mm (0.0004 in.)
3.
REMOVE SNAP RING
4.
SST
Q05201
REMOVE REAR BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER
RING FROM INPUT SHAFT
(a) Using SST and a press, remove the 4th gear and rear
bearing.
SST 0995000020
(b) Remove the needle roller bearings, spacer and synchronizer ring.
5.
REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.
http://vnx.su
MX21
INPUT SHAFT
6.
SST
CM0064
REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR

SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
Using SST and a press, remove the No.2 hub sleeve, 3rd gear,
synchronizer ring and needle roller bearings.
SST 0995000020
NOTICE:
Be careful not to mistake the 3rd gear synchronizer ring for
the 4th gear synchronizer ring.
7.
REMOVE NO.2 HUB SLEEVE, SHIFTING KEY AND

Using a screwdriver, remove the 3 shifting keys and 2 springs
SM0269
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MX22
INPUT SHAFT
MX03A04
INSPECTION
1.
(a)
(b)
WM0064
INSPECT SYNCHRONIZER RING

NOTICE:
off after rubbing.
(d)
WM0065

Minimum clearance:
3rd gear: 0.65 mm (0.0256 in.)
4th gear: 0.75 mm (0.0295 in.)
NOTICE:
off after rubbing.
2.
INSPECT NO.2 SHIFT FORK AND HUB SLEEVE

CLEARANCE
hub sleeve.
WM0066
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MX23
INPUT SHAFT
3.
(a)
(b)
SM0182
INSPECT INPUT SHAFT

Part A: 26.987 mm (1.0625 in.)
Part B: 32.484 mm (1.2789 in.)
Part C: 33.100 mm (1.3031 in.)
Part D: 29.987 mm (1.1806 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(c)

If the runout exceeds the maximum, replace the input shaft.
CM0013
http://vnx.su
MX24
INPUT SHAFT
MX03B04
REASSEMBLY
Engine
Side
SM0282
HINT:
reassembly.
1.
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Install the key springs positioned so that their end gaps are
not in line.
2.
INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring (for the 3rd gear) on the gear
and align the ring slots with the shifting keys.
NOTICE:
Do not install the synchronizer ring for 4th gear.
SM0193
(c)
Using a press, install the 3rd gear and No.2 hub sleeve.
Z00419
http://vnx.su
MX25
3.
(a)
INPUT SHAFT
INSTALL SNAP RING

Mark
Thickness mm (in.)
1.952.00 (0.07680.0787)
2.002.05 (0.07870.0807)
2.052.10 (0.08070.0827)
2.102.15 (0.08270.0846)
2.152.20 (0.08460.0866)
2.202.25 (0.08660.0886)
Z00604
(b)
4.
Using a snap ring expander, install the snap ring.

INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX20)
5.
INSTALL SYNCHRONIZER RING, NEEDLE ROLLER

BEARING, SPACER, 4TH GEAR AND REAR BALL
BEARING
Apply gear oil to the needle roller bearings.
Install the spacer and needle roller bearings.
Place the synchronizer ring on the gear.
(a)
(b)
(c)
SM0189
HINT:
Align the ring slots with the shifting keys and the ring projections
with the hub slots.
SM0190
(d)

SST 0960800071
SST
SM0049
http://vnx.su
MX26
6.
(a)
INPUT SHAFT
INSTALL SNAP RING

Mark
Thickness mm (in.)
2.152.20(0.08460.0866)
2.202.25(0.08660.0886)
2.252.30(0.08860.0906)
2.302.35(0.09060.0925)
2.352.40(0.09250.0945)
SM0050
(b)
7.

INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX20)
http://vnx.su
MX27
OUTPUT SHAFT
OUTPUT SHAFT
MX03C04
COMPONENTS
Output Shaft
Spacer
1st Gear
Synchronizer Ring
No.1 Hub Sleeve
Shifting Key
Shifting Key Spring

No.1 Clutch Hub
Ball
Spacer
Rear Bearing
Synchronizer Ring
2nd Gear
2nd Gear Bushing
3rd Driven Gear

4th Driven Gear
http://vnx.su
Q02544
MX28
OUTPUT SHAFT
MX03D03
DISASSEMBLY
1.
2nd Gear
1st Gear
Q05794
INSPECT 1ST AND 2ND GEARS THRUST CLEARANCES

Maximum clearance:
1st gear: 0.29 mm (0.0114 in.)
2nd gear: 0.34 mm (0.0134 in.)
Minimum clearance:
1st gear: 0.10 mm (0.0039 in.)
2nd gear: 0.10 mm (0.0039 in.)
2.
SM0137
SST
INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCES

the gear and shaft.
Maximum clearance:
0.051 mm (0.0020 in.)
Minimum clearance:
0.009 mm (0.0004 in.)
3.
REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR
AND OUTPUT GEAR SPACER
(a) Using SST and a press, remove the rear ball bearing and
4th driven gear.
SST 0995000020
(b) Remove the output gear spacer and ball.
CM0065
4.
SST
(a)
(b)
(c)
REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING AND SYNCHRONIZER RING
Shift the No.1 hub sleeve into the 1st gear.
Using SST and a press, remove the 3rd driven gear and
2nd gear.
SST 0995000020
Remove the needle roller bearing and synchronizer rings.
MT0063
http://vnx.su
MX29
5.
(a)
(b)
(c)
OUTPUT SHAFT
REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND LOCKING BALL
Using a press, remove the No.1 hub sleeve, 1st gear and
synchronizer ring.
Remove the needle roller bearing and locking ball.
Using a screwdriver and hammer, drive out the thrust
washer.
Z00427
6.
REMOVE NO.1 HUB SLEEVE, 3 SHIFTING KEYS AND

SPRINGS FROM NO.1 CLUTCH HUB
Q02948
http://vnx.su
MX30
OUTPUT SHAFT
MX03E04
INSPECTION
1.
(a)
(b)
WM0064

NOTICE:
off after rubbing.
(d)
WM0065

the synchronizer ring back and the gear spline end.
NOTICE:
off after rubbing.
2.
(a)
(b)

MT0780
(c)

MT0787
http://vnx.su
MX31
OUTPUT SHAFT
3.
INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE

hub sleeve.
WM0066
4.
(a)
A
CM0014

Part A: 31.984 mm (1.2592 in.)
Part B: 37.984 mm (1.4954 in.)
Part C: 32.002 mm (1.2599 in.)
If the outer diameter is less than the minimum, replace the output shaft.
(b)

If the runout exceeds the maximum, replace the output shaft.
CM0015
http://vnx.su
MX32
OUTPUT SHAFT
MX03F04
REASSEMBLY
Front
Q02949
HINT:
reassembly.
1.
HINT:
Position the identification groove of the hub sleeve to the front
of the transmission.
2.
(a)
SST
(b)
INSTALL THRUST WASHER, 1ST GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND NO.1
HUB SLEEVE TO OUTPUT SHAFT
Using SST and a press, install the thrust washer.
SST 0931660011 (0931600041)
Apply gear oil to the needle roller bearing.
SM0199
(c)
(d)
3.
Using a press, install the 1st gear and No.1 hub sleeve.
INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX28)
Z00428
Z00429
http://vnx.su
MX33
OUTPUT SHAFT
4.
MT0792
INSTALL SYNCHRONIZER RING, 2ND GEAR,

NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
(a) Install the ball.
(b) Fit the 2nd gear bushing groove securely over the ball
when installing the 2nd gear bushing on the shaft.
(c) Place the synchronizer rings on the 2nd gear.
(d) Apply gear oil to the needle roller bearing and install it.
(e) Install the 2nd gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
(f)
5.
SST
Using SST and a press, install the 3rd driven gear.

SST 0931660011 (0931600011)
INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX28)
SM0201
6.
(a)
(b)
INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN

GEAR AND RADIAL BALL BEARING
Install the outer gear spacer.
Using a press, install the 4th driven gear and bearing.
Z00431
7.
INSTALL REAR BEARING
Using SST and a press, install the rear bearing.
SST 0961222011
SST
SM0202
http://vnx.su
MX34

MX03G04
COMPONENTS
Shift and Select Lever Shaft
Ering
Select Spring Seat
Compression Spring
6.4 (85, 56 in.lbf)
Compression Spring
Dust Boot
Washer
Ering
Slotted Spring Pin
Shift Inner Lever No.1

Shift Inner Lever No.2
z Oil Seal
Select Spring Seat No.2

Nm(kgfcm, ftlbf) : Specified torque
z Nonreusable part
MP Grease
Control Shaft Cover

z Oring
Lever Lock Pin

Control Shaft Lever
37 (375, 27)
Q10277
http://vnx.su
MX35
DIFFERENTIAL CASE
DIFFERENTIAL CASE
MX03H04
COMPONENTS
Shim
z Outer Race and Side Bearing
Ring Gear
Pinion Gear
Pinion Shaft
83 (850, 61)
x8
z Side Bearing and Outer Race
Shim
Side Gear
Side Gear Thrust Washer
Differential Case
Straight Pin
Speed Sensor Drive Gear
z Nonreusable part
Z19302
http://vnx.su
MX36
DIFFERENTIAL CASE
MX03I04
DISASSEMBLY
SST
1.
(a)
Q08148
(b)
2.
(a)
(b)
(c)
Speed Sensor Drive Gear Side:

REMOVE SIDE BEARING FROM DIFFERENTIAL
CASE
Using SST, remove the bearing from the drive gear side
of the case.
SST 0995000020, 0995000030
Remove the speed sensor drive gear.
REMOVE RING GEAR
Place matchmarks on the ring gear and case.
Remove the 8 bolts.
it from the case.
3.
SST
Ring Gear Side:

CASE
Using SST, remove the bearing from the ring gear side of the
case.
SST 0995000020, 0995000030
Q04969
AT2799
4.
while holding one pinion toward the case.
Standard backlash: 0.050.20 mm (0.00200.0079 in.)
5.
(a) Using a pin punch and hammer, drive out the straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions and side gears with the 4 thrust
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MX37
6.
(a)
SST
DIFFERENTIAL CASE

IF NECESSARY, REPLACE DIFFERENTIAL SIDE
BEARING RETAINER OIL SEAL
Using SST and a hammer, drive out the oil seal from the
retainer.
SST 0995060020 (0995100680), 0995070010
(0995107150)
Q08145
(b)
(c)
Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 0935032014 (0935132130, 0935132150)
SST
SM0286
7.
(a)
(b)
SST
(c)

IF NECESSARY, REPLACE SIDE OIL SEAL
Using a screwdriver and hammer, drive out the oil seal.
Using SST and a hammer, drive in a new oil seal until its
surface is flush with the case surface.
SST 0935032014 (0935132130, 0935132150)
SM0155
8.
(a)
(b)
(c)
Z00442
(d)
(e)
SST
(f)
(g)

IF NECESSARY, REPLACE SIDE BEARING OUTER
RACE
Using a brass bar and hammer, drive out the bearing outer race.
Install the bearing retainer without an Oring.
Place the thinnest shim into the case.
Using SST and a press, install a new bearing outer race.
SST 0995060020 (0995100680), 0995070010
(0995107150)
Remove the 6 bolts.
Remove the bearing retainer and shim.
MT0634
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MX38
9.
(a)
(b)
(c)
SST
Q08184
DIFFERENTIAL CASE

IF NECESSARY, REPLACE SIDE BEARING OUTER
RACE
Using a brass bar and hammer, drive out the bearing outer race and shim.
Place the shim into the case.
Using SST and a press, install a new bearing outer race.
SST 0995060020 (0995100680), 0995070010
(0995107150)
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MX39
DIFFERENTIAL CASE
MX03J04
REASSEMBLY
1.
(a)
(b)

Install the correct thrust washers and side gears. Refer to
the table below, select thrust washers which will allow that
the backlash is within the specification. Try to select
washers of the same size for both sides.
Thickness mm (in.)
Thickness mm (in.)
0.95 (0.0374)
1.10 (0.0433)
1.00 (0.0394)
1.15 (0.0453)
1.05 (0.0413)
1.20 (0.0472)

case.
(c)
AT2981
Inspect the side gear backlash.

Using a dial indicator, measure the side gear backlash
while holding one pinion gear toward the case.
(d) Using a pin punch and hammer, drive in the straight pin
through the case and hole in the pinion shaft.
(e) Stake the differential case.
2.
(a) Clean the contact surface of the differential case and the
threads of the ring gear and differential case.
(b) Heat the ring gear in boiling water.
(c) Carefully remove the ring gear from the water.
(d) After moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT:
Align the matchmark on the differential case with the one on the
ring gear.
(e) Temporarily install the 8 bolts.
NOTICE:
The ring gear set bolts should not be torqued until the ring
gear has cooled sufficiently.
(f)
gear set bolts.
Q08147
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MX40
DIFFERENTIAL CASE
3.
(a)
INSTALL SIDE BEARING TO DIFFERENTIAL CASE

Using SST and a press, install a new side bearing to the
transmission case side.
SST 0931660011 (0931600011), 0935032014
(0935132120)
(b)
Install the speed sensor drive gear to the transaxle case

side.
SST
SM0287
Case Side
Q08649
(c)
SST
SM0289
Using SST and a press, install a new side bearing to the

transaxle case side.
SST 0931660011 (0931600011), 0935032014
(0935132120)
NOTICE:
Install the black cage bearing on the speed sensor drive
gear side.
4.
ADJUST DIFFERENTIAL CASE SIDE BEARING PRELOAD
(a) Install the differential to the transaxle case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
(d) Install the shim into the transmission case.
(e) Install the bearing retainer without an Oring.
(f)
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MX41
DIFFERENTIAL CASE
(g)
SST
Z00620
Using SST and a torque wrench, measure the preload.

SST 0956432011
1.01.6 Nm (1016 kgfcm, 8.713.9 in.lbf)
If the preload is not within the specification, remove the transmission case side bearing retainer. Select another shim.
HINT:
The preload will change by approx. 0.30.4 Nm (34 kgfcm,
2.63.5 in.lbf) corresponding to a change of 0.05 mm in shim
thickness.
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
1.90 (0.0748)
11
2.40 (0.0945)
1.95 (0.0768)
12
2.45 (0.0965)
2.00 (0.0787)
13
2.50 (0.0984)
2.05 (0.0807)
14
2.55 (0.1004)
2.10 (0.0827)
15
2.60 (0.1024)
2.15 (0.0846)
16
2.65 (0.1043)
2.20 (0.0866)
17
2.70 (0.1063)
2.25 (0.0886)
18
2.75 (0.1083)
2.30 (0.0906)
19
2.80 (0.1102)
10
2.35 (0.0925)
(h)
(i)
(j)
(k)
Remove
Remove
Remove
Remove
the
the
the
the
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6 bolts.
bearing retainer and shim.
17 bolts.
transmission case.
MX42

MX03K03
COMPONENTS
Shift Lever Knob
Parking Brake Cover
Cap
12 (120, 9)
Clip
Cap
4.9 (50, 43in.lbf)
Air Duct
Clip
Washer
Shift Cable Grommet

Shift Control Cable
Clip
Clip
Shift Cable Grommet

Retainer
Washer
Clip Washer
z Gasket
4.9 (50, 43in.lbf)
43 (430, 32)
Heat Insulator
z Rivet
z
Spring
Exhaust Pipe
62 (630, 46)

z Nonreusable part

D09356
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AUTOMATIC TRANSAXLE (A246E)

AUTOMATIC TRANSAXLE SYSTEM . . . . . . .
NEUTRAL START SWITCH . . . . . . . . . . . . . . .
VALVE BODY ASSEMBLY . . . . . . . . . . . . . . . .
DIFFERENTIAL OIL SEAL . . . . . . . . . . . . . . . .
AX1
AX3
AX4
AX7
SHIFT LOCK SYSTEM . . . . . . . . . . . . . . . . . . .

FLOOR SHIFT ASSEMBLY (LHD) . . . . . . . . . .
FLOOR SHIFT ASSEMBLY (RHD) . . . . . . . . .
AUTOMATIC TRANSAXLE UNIT . . . . . . . . . . .
AX8
AX11
AX20
AX28
TORQUE CONVERTER AND

DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . .
AX33
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AX1
AUTOMATIC TRANSAXLE SYSTEM

AX02L04
PRECAUTION
If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.
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AX2

AX02M06
OPERATION
Forward Clutch (C1)

No.2 OneWay Clutch (F2)
2nd Coast Brake (B1)
2nd Brake (B2)

1st and Reverse Brake (B3)
Direct Clutch (C2)
Front Planetary Gear Unit

No.1 OneWay Clutch (F1)
Rear Planetary Gear Unit
U/D Planetary Gear Unit
U/D Brake (B4)
U/D Clutch (C3)

U/D OneWay Clutch (F3)
Shift Lever
Range
Gear
No. 1
Solenoid
Valve
No. 2
Solenoid
Valve
C1
C2
Park
ON
OFF
Reverse
ON
OFF
Neutral
ON
ON
OFF
OFF
ON
ON
3rd
OFF
ON
O/D
OFF
OFF
1st
ON
OFF
2nd
ON
ON
3rd*
OFF
ON
1st
ON
OFF
B1
B2
B3
B4
F3
F
F
F
F
ON
F
F
F
F : Operating
*: Downshift only in the 3rd gear for the 2 range and 2nd gear for the L range no upshift
ON
2nd*
F2
F
F
F1
1st
2nd
C3
F
F
F
F
F
F
F
F
F
F00484
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AX3
NEUTRAL START SWITCH

AX0PK02
ONVEHICLE REPAIR
1.
REMOVE LH ENGINE UNDER COVER
2.
DISCONNECT SHIFT CABLE FROM CONTROL SHIFT

LEVER
DISCONNECT NEUTRAL START SWITCH CONNECTOR
3.
Q08545
4.
(a)
(b)
(c)
REMOVE NEUTRAL START SWITCH

Remove the nut, washer and control shaft lever.
Pry out the lock washer and remove the manual valve
shaft nut.
Remove the 2 bolts and pull out the neutral start switch.
D08573
5.
(a)
INSTALL AND ADJUST NEUTRAL START SWITCH

Install the neutral start switch with 2 bolts.
(b) Install a new lock plate and tighten the nut.
(c) Stake the nut with lock plate.
(d) Install the control shift lever, washer and nut.
6.
CONNECT NEUTRAL START SWITCH CONNECTOR
7.
CONNECT SHIFT CABLE TO CONTROL SHIFT LEVER
8.
CHECK NEUTRAL START SWITCH OPERATION
Check that the engine can be started with the shift lever only in
the N or P range, but not in other ranges.
If not as started above, carry out the adjustment procedure
(See page DI3).
9.
INSTALL LH ENGINE UNDER COVER
10. TEST DRIVE VEHICLE
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AX4
VALVE BODY ASSEMBLY
VALVE BODY ASSEMBLY

AX0PL02
ONVEHICLE REPAIR
1.
F00483
2.
REMOVE DRAIN PLUG AND DRAIN ATF
3.
REMOVE OIL PAN AND GASKET
NOTICE:
S
Some fluid will remain in the oil pan.
S
Remove all pan bolts, and carefully remove the oil
pan assembly.
S
Discard the gasket.
4.
REMOVE 2 MAGNETS FROM OIL PAN
5.
EXAMINE PARTICLES IN PAN
Remove the magnets and use them to collect any steel chips.
Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic): bearing, gear and plate wear
Brass (nonmagnetic): bushing wear
6.
REMOVE OIL STRAINER
Remove the 3 bolts and oil strainer.
NOTICE:
Be careful as some fluid will come out with the oil strainer.
D08576
7.
(a)
(b)
DISCONNECT SOLENOID CONNECTOR

Remove the 2 bolts and wire retainers.
Disconnect the 4 solenoid connecters.
D08577
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AX5
VALVE BODY ASSEMBLY
8.
REMOVE MANUAL DETENT SPRING
Remove the bolt and manual detent spring.
F00673
9.
(a)
REMOVE VALVE BODY

(b)
While disconnecting the manual valve connecting rod

from the manual valve lever, remove the valve body with
the manual valve together.
INSTALL VALVE BODY
While connecting the manual valve connecting rod to the
manual valve lever, install the valve body with the manual
valve together.
D08579
10.
(a)
AT5616
A
C
A
(b)
Install the 17 bolts.

Bolt length:
A: 20 mm (0.79 in.)
B: 28 mm (1.10 in.)
C: 50 mm (1.97 in.)
A
D08579
11. INSTALL MANUAL DETENT SPRING

Install the manual detent spring and bolt.
12. CONNECT 4 SOLENOID CONNECTORS
(a) Connect the 4 solenoid connectors.
(b) Install the wire retainer and bolt.
F00673
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AX6
VALVE BODY ASSEMBLY
13. INSTALL OIL STRAINER

Install the oil strainer with the 3 bolts.
Bolt length:
A bolt: 12 mm (0.47 in.)
B bolt: 20 mm (0.79 in.)
B
D08576
14.
15.
(a)
(b)
16.
D08582
17.
18.
INSTALL MAGNETS IN OIL PAN

INSTALL OIL PAN AND GASKET
Install a new gasket to the oil pan and install them to the
transaxle.
Install the 18 bolts.
INSTALL DRAIN PLUG
FILL ATF AND CHECK FLUID LEVEL (See page
DI3)
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AX7
DIFFERENTIAL OIL SEAL

AX02R06
ONVEHICLE REPAIR
1.
2.
3.
DRAIN ATF
REMOVE LH AND RH DRIVE SHAFTS (See page
SA3)
F00483
4.
REMOVE LH AND RH OIL SEAL
Using SST, drive out the oil seal.
SST 0930800010
SST
Z02840
5.
(a)
LH side
(b)
SST
INSTALL LH SIDE OIL SEAL

Using SST, drive in a new oil seal.
SST 0935032014 (0935132111, 0935132130)
Oil seal drive in depth:
5.3 0.5 mm (0.209 0.020 in.)
Z02841
6.
(a)
RH side
SST
(b)
7.
Z04055
8.
9.
INSTALL RH SIDE OIL SEAL

Using SST, drive in a new oil seal until SST makes contact
with the case surface.
SST 0935032014 (0935132130, 0935132150)
Oil seal drive in depth:
3.1 0.5 mm (0.122 0.020 in.)
INSTALL LH AND RH DRIVE SHAFTS (See page
SA12)
FILL AND CHECK FLUID LEVEL (See page DI3)
INSTALL LH AND RH ENGINE UNDER COVERS
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AX8
SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM

AX10R01
LOCATION
Key Interlock Solenoid

Stop Light Switch
Shift Lock Control Computer
D10026
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AX9
SHIFT LOCK SYSTEM

AX10S01
INSPECTION
5 (IG)
1 (ACC)
4 (KLS+)
3 (E)
2 (STP)
Wire harness side
LHD:
INSPECT SHIFT LOCK CONTROL COMPUTER
Using a voltmeter, measure the voltage at each terminal.
HINT:
Do not disconnect the shift lock control computer connector.
D00758
Terminal
1 3 (ACC E)
1.
Measuring Condition
Voltage (V)
Ignition switch ACC
10 14
Ignition switch ON
10 14
2 3 (STP E)
Depressing brake pedal
10 14
4 3 (KLS+ E)
(1) Ignition switch ACC and P range

(2) Ignition switch ACC and except P range
(3) Ignition switch ACC and except P range (After approx. 1 second)
0
7.5 11
6 9.5
5 3 (IG E)
2.
RHD:
HINT:
Do not disconnect the shift control computer connector.
D05910
Terminal
2 3 (ACC E)
4 3 (IG E)
Measuring Condition
Voltage (V)
Ignition switch ACC
10 14
Ignition switch ON
10 14
5 3 (STP E)
10 14
1 3 (KLS+ E)

0
7.5 11
6 9.5
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AX10
KLS+
SHIFT LOCK SYSTEM
3.
(a)
(b)
INSPECT KEY INTERLOCK SOLENOID

Disconnect the solenoid connector.
Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 12.5 16.5
If the resistance value is not as specified, replace the solenoid.
KLS
D08869
(c)
KLS+
Provide the battery voltage between the terminals.

Check that the solenoid can be heard its operating.
If the operation is not as specified, replace the solenoid.
KLS
D08870
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AX11
FLOOR SHIFT ASSEMBLY (LHD)

AX02U07
COMPONENTS
Parking Brake Cover
12 (120, 9)
Clip
Shift Control Cable
Cap
Rear Console Box

D10190
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AX12
Pattern Select Switch
Position Indicator
Upper Housing
Shift Lever Knob Subassembly

Spring
Shift Lever Knob

Sleeve
Shift Lever Button
Detent Rod
Position Indicator
Slide Cover
O/D Main Switch

L
Position
Spring
Indicator Plate
Position Indicator
Lower Housing
Cap
Shift Lever Knob Cover

Bulb
Grooved Pin
Spring Plate
Indicator Light
Wire
Shift Lever Subassembly
Shift Lever Plate
Shift Lock Release Button
Spring
Shift Lock
Control Computer
Control Shaft
MP grease
L Precoated part
Collar
D09906
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AX13

AX10T01
REMOVAL
1.
2.
(a)
(b)
REMOVE REAR CONSOLE (See page BO8)

REMOVE SHIFT LEVER ASSEMBLY
Disconnect the 3 connectors and wire harness.
Remove the clip and disconnect the shift control cable.
(c)
Remove the 4 bolts and floor shift assembly.

D02081
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AX14

AX0C503
DISASSEMBLY
1.
(a)
(b)
(c)
2
1
Secondary Locking Device
REMOVE O/D MAIN SWITCH TERMINAL

Remove the O/D main switch connector from the shift lever plate.
Disengage the secondary locking device.
Release the locking lug of the terminals 2 and 4, and pull
the terminals out from the rear.
A00451
2.
REMOVE SHIFT LEVER KNOB SUBASSEMBLY
(a) Remove the 2 screws and shift lever knob subassembly.
NOTICE:
Pay attention not to put unnatural load onto O/D main
switch wire harness.
(b) Remove the shift lever knob cover.
(c) Remove the shift lever button and spring.
(d) Remove the O/D main switch.
3.
REMOVE INDICATOR LIGHT WIRE
4.
REMOVE CAP AND BULB FROM INDICATOR LIGHT
WIRE
5.
REMOVE INDICATOR HOUSING
Remove the screws and an indicator housing.
6.
(a)
(b)
(c)
(d)
(e)
DISASSEMBLE INDICATOR HOUSING

Remove the pattern select switch.
Remove the position indicator lower housing.
Remove the shift lock release button and spring.
Remove the position indicator slide cover.
Remove the position indicator plate.
D08694
7.
REMOVE SHIFT LOCK CONTROL COMPUTER
Remove the 2 screws and shift lock control computer.
8.
REMOVE SPRING PLATE
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AX15
9.
(a)
(b)
REMOVE SHIFT LEVER SUBASSEMBLY

Using a screwdriver and a hammer, remove the control
shaft.
Remove the shift lever subassembly.
F00683
10.
(a)
DISASSEMBLE SHIFT LEVER SUBASSEMBLY

Measure the distance A between the lower edge of the
shift lever knob sleeve and the upper edge of the shift lever subassembly.
D04313
(b) Using a hammer, remove the grooved pin.

NOTICE:
When pressing down the grooved pin, if doing it at the
place other than the notch, there may be fear of damaging
the shift lever subassembly.
(c) Remove the detent rod and spring.
(d) Remove the shift lever knob sleeve from the detent rod.
F00687
11. REMOVE COLLARS

Using a screwdriver and a hammer, remove the 4 collars.
F00685
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AX16

AX0C603
REASSEMBLY
: Apply MP Grease
1.
2.
INSTALL COLLARS
INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT
ROD
3.
(a)
ASSEMBLE SHIFT LEVER SUBASSEMBLY

Apply MP grease on the compression spring, the detent
rod and the shift lever subassembly.
Install the spring and the detent rod to shift lever subassembly.
(b)
F00686
(c)
Place the shift lever subassembly as shown in the illustration.
F00684
Correct
(d) Insert the grooved pin in the detent rod pin hole.
NOTICE:
S
Assemble the grooved pin to ensure that it fits into the
guide hole of the shift lever subassembly in parallel.
S
Take care not to insert the pin in the wrong direction
of the detent rod.
Wrong
F00688
(e)
Meet the grooved pin with the notch of the guide hole.
F00689
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AX17
(f)
Press the pin with a hammer.

A: 10.0 10.4 mm (0.39 0.41 in.)
NOTICE:
When pressing in the grooved pin, if doing it at the place
other than the notch, the shift lever subassembly might be
damaged.
4.
CHECK DETENT ROD OPERATION
Shift Lever
Subassembly
A
Detent Rod
A00452
Grooved Pin
F01188
5.
INSTALL SHIFT LEVER KNOB SLEEVE DETENT ROD
Drive the shift lever knob sleeve to the distance A measured before removal.
D04313
6.
(a)
: Apply MP Grease
INSTALL SHIFT LEVER SUBASSEMBLY

Apply MP grease.
F00690
(b)
Using a brass bar and a hammer, install the control shaft

and the shift lever subassembly to the shift lever plate.
NOTICE:
Take care not to install them in the wrong direction of the
shift lever subassembly.
7.
INSTALL SPRING PLATE
F00691
8.
INSTALL SHIFT LOCK CONTROL COMPUTER
Install the shift control control computer and 2 screws.
NOTICE:
Install the grooved pin into the groove of the shift lock unit
as shown in the illustration.
F00692
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AX18
9.
ASSEMBLE INDICATOR HOUSING
(a) Install the position indicator plate.
(b) Install the position indicator slide cover.
(c) Install the spring and shift lock release button.
(d) Install the position indicator lower housing.
(e) Install the pattern select switch.
NOTICE:
Do not make indicator housing dirty with MP grease.
10. INSTALL INDICATOR HOUSING
Install the screws and an indicator housing.
11. INSTALL CAP AND BULB TO INDICATOR LIGHT WIRE
12. INSTALL INDICATOR LIGHT WIRE
13. INSTALL SHIFT LEVER KNOB SUBASSEMBLY
(a) Install the O/D main switch.
(b) Install the spring and shift lever button.
(c) Install the shift lever knob cover.
HINT:
Apply MP grease to shift lever knob button.
(d) Install the shift lever subassembly and 2 screws.
HINT:
Coat the threads of the screws with sealant.
Sealant:
242 or equivalent
NOTICE:
Make sure not to catch O/D main switch wire harness.
(e) Install the O/D main switch wire harness securely to hung
on the hook of the shift lever subassembly.
14. INSTALL O/D MAIN SWITCH TERMINAL
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AX19

AX02Y07
INSTALLATION
With the brake pedal depressed,

shift while holding the lock
release button in. (The ignition
switch must be in ON position.)
Shift while holding the lock
release button in.
Shift normally
D02013
INSTALL FLOOR SHIFT ASSEMBLY

Installation is in the reverse order of removal (See page
AX13).
HINT:
After installation, adjust shift lever ranges (See page DI3) and
inspect shift lever operation.
S
When shifting it to each range, make sure that the shifting
lever moves smoothly, can be moderately operated and
the range indicator displays correctly.
Ranges which can be operated without pressing the
shift lever nob button
R N D 2
Ranges which can be operated only with pressing the
P R, 2 L, N R P
S
When starting the engine, make sure that the vehicle
moves forward when shifting from N to D range, and
moves rearward when shifting to R range.
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AX20
FLOOR SHIFT ASSEMBLY (RHD)

AX01B03
COMPONENTS
12 (120, 9)
Clip
Rear Console Box

Shift Control Cable
Shift Lever
Assembly
Cap
Parking Brake Cover

D02091
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AX21
Shift Lever Button

Spring
Shift Lever Knob
Position Indicator Plate
Position Indicator
Upper Housing
L
O/D Main
Switch
Position Indicator
Slide Cover
Bulb
Detent Rod
Shift Lever Knob

Cover
Indicator Light Wire

Spring
Stopper Pin
Control Shaft
Detent Roller
Holder
Spring
Shift Lever SubAssembly
Shift Lock Plate

Spring
Shift Lever
Plate
Collar
x4
MP grease
L Precoated part
D09907
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AX22

AX10U01
REMOVAL
1.
2.
(a)
(b)

REMOVE FLOOR SHIFT ASSEMBLY
Disconnect the connectors.
(c)
Remove the 4 bolts and shift lever assembly.

D02093
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AX23

AX10V01
DISASSEMBLY
1.
(a)
2
1
A00451

Remove O/D main switch connector from the shift lever
plate.
(b) Disengage the secondary locking device.
(c) Disengage the locking lug of the terminals 2 and 4, and
pull the terminals out from the rear.
2.
NOTICE:
Pay attention not to apply unnatural load onto O/D main
(b) Remove the Shift lever knob cover.
(c) Remove the Shift lever button and spring.
3.
4.
REMOVE BULB FROM INDICATOR LIGHT WIRE
5.
REMOVE INDICATOR HOUSING SUBASSEMBLY
6.
(a)
(b)
(c)
DISASSEMBLE INDICATOR HOUSING SUBASSEMBLY

Remove the position indicator side cover.
D02094
7.
D09908
8.
REMOVE STOPPER PIN, DETENT ROD AND SPRING
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AX24
9.
(a)
(b)

Using an extension bar and hammer, remove the control
shaft.
10.
(a)
(b)

Remove the Detent roller holder.
Remove the Compression spring.
D02095
D02096
11. REMOVE COLLARS

Using an extension bar and hammer, remove the 4 collars.
D02040
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AX25

AX10W01
REASSEMBLY
: Apply MP Grease
1.
INSTALL COLLARS
2.
(a)

Apply the MP grease to the detent roller holder, compression spring and shift lever subassembly.
Install the compression spring to the detent roller holder.
Install the detent roller holder with the compression spring
to the shift lever subassembly.
(b)
(c)
D02096
3.
(a)
: Apply MP Grease
(b)

Apply the MP grease to the control shaft and shift lever
subassembly.
Using an extension bar and hammer, install the control
shaft and shift lever subassembly to the shift lever plate.
D02041
4.
(a)
(b)
INSTALL SPRING, DETENT ROD AND STOPPER PIN

Apply the MP grease to the detent rod and stopper pin.
Install the compression spring and detent rod to the shift
lever subassembly.
(c) Insert the stopper pin in the stopper pin hole.
NOTICE:
against the detent rod.
5.
Install the shift lock control computer with 3 screws.
6.
CHECK SHIFT LEVER OPERATION
7.
ASSEMBLE INDICATOR HOUSING SUBASSEMBLY
(a) Install the pattern select switch.
(b) Install the position indicator plate.
(c) Install the position indicator slide plate.
8.
INSTALL INDICATOR HOUSING SUBASSEMBLY
9.
INSTALL BULB TO INDICATOR LIGHT WIRE
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AX26

HINT:
Apply MP grease to the shift lever knob button.
(b) Install the shift lever button and spring.
(d) Install the shift lever knob subassembly and 2 screws.
HINT:
Sealant:
242 or equivalent
NOTICE:
(e) Install the O/D main switch wire harness securely and
hang it on the hook of the shift lever subassembly.
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AX27

AX01F03
INSTALLATION

release button in.
Shift normally
D02013

AX22).
HINT:
After installation, adjust shift lever ranges (See page DI3) and
inspect shift lever operation.
S
R N D 2
P R, 2 L, N R P
S
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AX28
AUTOMATIC TRANSAXLE UNIT

AX02Z04
COMPONENTS
Battery
RH Drive Shaft
Air Cleaner Assembly
87 (890, 64)
13 (130, 9)
39 (400, 29)
Torque Converter Clutch

28 (290, 21)
25 (250, 18)
64 (650, 47)
64 (650, 47)
46 (470, 34)
52 (530, 38)
x6
18 (185, 13)
Ground Cable
39 (400, 29)
Hole Plug
87 (890, 64)
z Snap Ring
LH Drive Shaft
23 (230, 17)
225 (2,305, 167)
Starter
Control Cable
z Cotter Pin
Plug for
Hydraulic Test
Clip
64 (650, 47)
Lock Nut Cap
Exhaust Front Pipe

12 (120, 9)
z Gasket
62 (630, 46)
43 (440, 32)
127 (1,300, 94)
Engine Under Cover RH

Suction Hose (RHD)
Front Center Member
z
62 (630, 46)
73 (740, 54)
Engine Under Cover LH
Grommet
x5
72 (740, 53)
Grommet
Front Center Member
Protector
73 (740, 54)
x5
z Nonreusable part
39 (400, 29)
D10025
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AX29

AX10X01
REMOVAL
1.
2.
3.
REMOVE BATTERY
REMOVE AIR CLEANER
REMOVE GROUND CABLE
4.
REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING

BOLTS FROM TRANSAXLE SIDE
REMOVE UPPER SIDE STARTER MOUNTING BOLT
DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
5.
6.
7.
F00497
8.
9.

SA3)
F00483
10.
(a)
(b)
11.
(a)
F00705
(b)
12.
(a)
DISCONNECT SOLENOID CONNECTOR AND NEUTRAL START SWITCH CONNECTOR

Disconnect the solenoid connector and the neutral start
switch connector.
Remove the wire harness clamps.
REMOVE SHIFT CONTROL CABLE
Remove the nut from the control shift lever.
Remove the clip and disconnect the control cable.
REMOVE FRONT CENTER MEMBER
RHD:
Remove the nut and disconnect the suction hose from the
front center member.
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AX30
(b)
Remove the 9 bolts, 3 grommets, front center member

protector and front center member.
Torque:
A: 73 Nm (740 kgfcm, 54 ftlbf)
B: 39 Nm (400 kgfcm, 29 ftlbf)
C: 72 Nm (740 kgfcm, 53 ftlbf)
13.
(a)
(b)
REMOVE STARTER
Remove the nut and cable, and disconnect the connector.
Remove the bolt and the starter.
14.
B
D02064
F00482
F00496
15.
REMOVE UPPER SIDE ENGINE LEFT MOUNTING

BOLT
16. REMOVE OIL COOLER HOSE
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
D00655
17. REMOVE HEAT INSULATOR

Remove the 2 bolts and a nut.
F00493
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AX31
18.
JACK UP TRANSAXLE
19.
(a)
(b)
REMOVE TRANSAXLE
Remove the hole plug.
Turn the crankshaft to gain access and remove the 6 bolts
holding the crankshaft pulley set bolt with a wrench.
F00479
HINT:
First install green colored bolt and then 5 other bolts.
F00478
(c)
(d)
A
B
Remove the 4 bolts.

Torque:
Lower the engine to move it to the left side and remove
the transaxle from the engine.
F00477
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AX32

AX03105
INSTALLATION
F00502
1.
CHECK TORQUE CONVERTER INSTALLATION
Using calipers and a straight edge, measure the distance between the installed surface and the front surface of the transaxle housing.
Correct distance: More than 15.5 mm (0.610 in.)
2.
TRANSAXLE INSTALLATION
AX29).
HINT:
S
After installation, adjust the shift control cable and neutral
start switch (See page DI3).
S
Fill ATF and check fluid level (See page DI3).
S
Perform the test drive of the vehicle (See page DI3).
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AX33
TORQUE CONVERTER AND DRIVE PLATE
TORQUE CONVERTER AND DRIVE

PLATE
SST
AX03204
INSPECTION
1.
(a)
AT0953
Hold
Lock
Turn
INSPECT ONEWAY CLUTCH

Install SST into the inner race of the oneway clutch.
SST 0935032014 (0935132010)
(b) Install SST so that it fits in the notch of the converter hub
and outer race of the oneway clutch.
SST 0935032014 (0935132020)
(c) With the torque converter setting up on its side, check that
the oneway clutch locks when it is turned counterclockwise, and rotates smoothly clockwise.
If necessary, clean the converter and retest the oneway
clutch.
Replace the converter if the oneway clutch still fails the test.
Free
AT3306
2.
MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
If the runout is not within the specification or ring gear is damaged, replace the drive plate.
Torque: 64 Nm (650 kgfcm 47 ftlbf)
F00487
F00488
3.
MEASURE TORQUE CONVERTER SLEEVE RUNOUT
Temporarily mount the torque converter to the drive plate. Set
up a dial indicator and measure the torque converter sleeve
runout.
If the runout is not within the specification, try to correct by reorienting the installation of the converter.
HINT:
Mark the position of the converter to ensure the correct installation.
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AUTOMATIC TRANSAXLE (U240E)

AUTOMATIC TRANSAXLE SYSTEM . . . . . . .
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . .
ATF TEMPERATURE SENSOR . . . . . . . . . . . .
NEUTRAL START SWITCH . . . . . . . . . . . . . . .
AX1
AX3
AX4
AX6
VALVE BODY ASSEMBLY . . . . . . . . . . . . . . . .

DIFFERENTIAL OIL SEAL . . . . . . . . . . . . . . . .
SHIFT LOCK SYSTEM . . . . . . . . . . . . . . . . . . .
FLOOR SHIFT ASSEMBLY (LHD) . . . . . . . . . .
AX8
AX12
AX13
AX16
FLOOR SHIFT ASSEMBLY (RHD) . . . . . . . . .

AUTOMATIC TRANSAXLE UNIT . . . . . . . . . . .
TORQUE CONVERTER AND
AX25
AX33
DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . .
AX38
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AX1

AX0LF01
PRECAUTION
If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.
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AX2

AX0LG03
OPERATION
1st & Reverse Brake (B2)
Forward Clutch (C1)
2nd Brake (B1)
Direct Clutch (C2)

No.1 Oneway Clutch (F1)
U/D Brake (B3)
U/D Oneway
Clutch (F2)
U/D Clutch (C3)
D05891
f ... Operating
Shift lever range
Gear range
Parking
Reverse
Neutral
2
L
C1
C2
C3
B1
B2
B3
F1
F2
f
f
f
f
1st
2nd
3rd
O/D
1st
2nd
1st
f
f
f
f
f
f
f
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f
f
AX3
SPEED SENSOR
SPEED SENSOR
AX0LI03
ONVEHICLE REPAIR
1.
REMOVE AIR CLEANER ASSEMBLY
2.
DISCONNECT COUNTER GEAR SPEED SENSOR

CONNECTOR
REMOVE COUNTER GEAR SENSOR
Remove the bolt and counter gear speed sensor.
3.
(a)
D05876
(b)
4.
(a)
Oring
(b)
5.
Remove the Oring from the counter gear speed sensor.

INSTALL COUNTER GEAR SPEED SENSOR
Coat a new Oring with ATF and install it to the counter
gear speed sensor.
Install the counter gear speed sensor with the bolt.
Torque: 11.3 Nm (115 kgfcm, 8 ftlbf)
CONNECT COUNTER GEAR SPEED SENSOR CONNECTOR
Q04733
6.
7.
(a)
DISCONNECT INPUT TURBINE SPEED SENSOR

CONNECTOR
REMOVE INPUT TURBINE SPEED SPEED SENSOR
Remove the bolt and input turbine speed sensor.
D05887
(b)
8.
(a)
Oring
(b)
9.
Q04733
10.
Remove the Oring from the input turbine speed sensor.

INSTALL INPUT TURBINE SPEED SENSOR
Coat a new Oring with ATF and install it to the input turbine speed sensor.
Install the input turbine speed sensor with the bolt.
CONNECT INPUT TURBINE SPEED SENSOR CONNECTOR
INSTALL AIR CLEANER ASSEMBLY
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AX4
ATF TEMPERATURE SENSOR

AX0LJ03
ONVEHICLE REPAIR
1.
2.
DISCONNECT SOLENOID CONNECTOR

D05886
3.
4.
NOTICE:
Remove the 18 bolts, and carefully remove the oil pan assembly. Discard the gasket.
D07261
5.
(a)
(b)
REMOVE OIL STRAINER

Remove the Oring.
D05879
6.
D02934
DISCONNECT 5 SHIFT SOLENOID VALVE CONNECTORS

7.
REMOVE ATF TEMPERATURE SENSOR
Remove the bolt and lock plate, and remove the ATF temperature sensor.
8.
SEPARATE WIRE HARNESS FROM 2 CLAMPS
9.
CLAMP WIRE HARNESS TO 2 CLAMPS
10. INSTALL ATF TEMPERATURE SENSOR
Install the ATF temperature sensor with the lock plate and bolt.
11. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS
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AX5
12.
(a)
(b)
INSTALL OIL STRAINER

Coat a new Oring with ATF.
Install the Oring to the oil strainer.
(c)

D05880
D05879
13. INSTALL OIL PAN

Install the oil pan and a new gasket with the 18 bolts.
14. INSTALL DRAIN PLUG
Install a new gasket and drain plug.
D07261
15.
CONNECT SOLENOID CONNECTOR
16.
17.
FILL ATF AND CHECK ATF LEVEL (See page DI62)

D05886
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AX6

AX0LK03
ONVEHICLE REPAIR
1.
2.
DISCONNECT NEUTRAL START SWITCH CONNECTOR
3.
(a)
REMOVE NEUTRAL START SWITCH

Remove the nut.
(b)
Remove the nut, washer and control shift lever.
(c)
(d)
Using a screwdriver, pry off the lock plate.

Remove the nut and lock plate.
D05911
D05912
D05913
D05914
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AX7
(e)
4.
(a)
(b)
(c)
Remove the 2 bolts and pull out the neutral start switch.
INSTALL AND ADJUST NEUTRAL START SWITCH
Install the neutral start switch with the 2 bolts.
Install a new lock plate and nut.
Bend the claws on the lock plate to fix the nut.
D05915
(d)
Install the control shift lever with the nut.

(e)
Connect the control cable to the control shaft.

5.
CONNECT NEUTRAL START SWITCH CONNECTOR
D05913
D05912
D05911
6.
CHECK NEUTRAL START OPERATION
Check that the engine can be started with the shift lever only in
the N or P range, but not in other position.
If the engine can not be stated not as started above, carry out
the adjustment procedure (See page DI62).
7.
INSTALL AIR CLEANER ASSEMBLY
8.
TEST DRIVE VEHICLE
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AX8
VALVE BODY ASSEMBLY
VALVE BODY ASSEMBLY

AX0LM03
ONVEHICLE REPAIR
1.
2.
3.
NOTICE:
Remove the 18 bolts, and carefully remove the oil pan assembly. Discard the gasket.
D07261
4.
EXAMINE PARTICLES IN OIL PAN
Remove the magnets and use them to collect any steel chips.
Look carefully at the chips and particles in the pan and on the
magnet to anticipate what type of wear you will find in the transaxle.
Steel (magnetic)...bearing, gear and plate wear
Brass (nonmagnetic)... bushing wear
AT0103
5.
(a)
(b)
REMOVE OIL STRAINER

Remove the Oring.
D05879
6.
DISCONNECT 5 SHIFT SOLENOID VALVE CONNECTORS

7.
REMOVE ATF TEMPERATURE SENSOR
Remove the bolt and lock plate, and remove the ATF temperature sensor.
8.
SEPARATE WIRE HARNESS FROM 2 CLAMPS
D02934
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AX9
VALVE BODY ASSEMBLY
9.
REMOVE VALVE BODY
Remove the 17 bolts and valve body.
NOTICE:
Be careful not to drop the check valve body, spring and accumulator piston.
D02935
10.
REMOVE CHECK BALL BODY AND SPRING
11.
REMOVE 2 APPLY GASKETS
D02936
D02937
D02938
12. REMOVE SHIFT SOLENOID VALVE

Remove the 5 bolts and 5 shift solenoid valves.
13. INSTALL SHIFT SOLENOID VALVE
Install the 5 shift solenoid valves with the 5 bolts.
Torque:
Bolt A: 6.6 Nm (67 kgfcm, 58 in.lbf)
Bolt B: 10.8 Nm (110 kgfcm, 8 ftlbf)
Bolt length:
Bolt A: 12 mm (0.47 in.)
Bolt B: 45 mm (1.77 in.)
14. INSTALL 2 APPLY GASKETS
(a) Coat 2 new apply gaskets with ATF.
(b) Install the 2 gaskets to the transaxle case.
D02937
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AX10
VALVE BODY ASSEMBLY
15.
INSTALL CHECK VALVE AND SPRING
16.
(a)
INSTALL VALVE BODY

Align the groove of the manual valve with the pin of the
manual valve lever.
Temporarily install the valve body with the 17 bolts.
Bolt length:
Bolt A: 25 mm (0.98 in.)
Bolt B: 41 mm (1.61 in.)
Bolt C: 45 mm (1.77 in.)
Check that the manual valve lever contacts the center of
the roller at the tip of the detent spring.
Tighten the 17 bolts.
CLAMP WIRE HARNESS TO 2 CLAMPS
D02936
A
C
A
(b)
C
B
B
B
D02935
(c)
(d)
17.
18. INSTALL ATF TEMPERATURE SENSOR

Install the ATF temperature sensor with the lock plate and bolt.
19. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS
D02934
20.
(a)
(b)
INSTALL OIL STRAINER

Coat a new Oring with ATF.
Install the Oring to the oil strainer.
D05880
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AX11
(c)
VALVE BODY ASSEMBLY

D05879
21. INSTALL MAGNET IN OIL PAN

Install the 3 magnets in the oil pan, as shown in the illustration.
D02940
22. INSTALL OIL PAN

Install the oil pan and a new gasket with the 18 bolts.
23. INSTALL DRAIN PLUG
Install a new gasket and drain plug.
D07261
24.
25.

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AX12

AX0LN02
ONVEHICLE REPAIR
1.
2.
DRAIN ATF
SA3)
D07261
3.
REMOVE LH AND RH SIDE OIL SEAL
Using SST, drive out both the side oil seals.
SST 0930810010
SST
D03284
4.
(a)
(b)
INSTALL LH SIDE OIL SEAL

SST 0935032014 (0935132130, 0935132150)
Oil seal drive in depth: 2.7 0.5 mm (0.106 0.020 in.)
SST
D05870
5.
(a)
(b)
6.
SST
7.
INSTALL RH SIDE OIL SEAL

SST 0922300010
Oil seal drive in depth: 0 0.5 mm (0 0.020 in.)
INSTALL LH AND RH DRIVE SHAFTS (See page
SA12)
D03286
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AX13
SHIFT LOCK SYSTEM
SHIFT LOCK SYSTEM

AX10Y01
LOCATION
Key Interlock Solenoid

Stop Light Switch
D10026
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AX14
SHIFT LOCK SYSTEM

AX10Z01
INSPECTION
5 (IG)
1 (ACC)
4 (KLS+)
3 (E)
2 (STP)
Wire harness side
LHD:
HINT:
Do not disconnect the shift lock control computer connector.
D00758
Terminal
1 3 (ACC E)
1.
Measuring Condition
Voltage (V)
Ignition switch ACC
10 14
Ignition switch ON
10 14
2 3 (STP E)
10 14
4 3 (KLS+ E)

0
7.5 11
6 9.5
5 3 (IG E)
2.
RHD:
HINT:
Do not disconnect the shift control computer connector.
D05910
Terminal
2 3 (ACC E)
4 3 (IG E)
Measuring Condition
Voltage (V)
Ignition switch ACC
10 14
Ignition switch ON
10 14
5 3 (STP E)
10 14
1 3 (KLS+ E)

0
7.5 11
6 9.5
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AX15
KLS+
SHIFT LOCK SYSTEM
3.
(a)
(b)
INSPECT KEY INTERLOCK SOLENOID

Disconnect the solenoid connector.
Using an ohmmeter, measure the resistance between the
terminals.
Standard resistance: 12.5 16.5
If the resistance value is not as specified, replace the solenoid.
KLS
D08869
(c)
KLS+
Provide the battery voltage between the terminals.

Check that the solenoid can be heard its operating.
If the operation is not as specified, replace the solenoid.
KLS
D08870
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AX16

AX02U08
COMPONENTS
Parking Brake Cover
12 (120, 9)
Clip
Shift Control Cable
Cap
Rear Console Box

D10190
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AX17
Position Indicator
Upper Housing
Shift Lever Knob Subassembly

Spring
Shift Lever Knob

Sleeve
Shift Lever Button
Detent Rod
Position Indicator
Slide Cover
O/D Main Switch

L
Position
Spring
Indicator Plate
Position Indicator
Lower Housing
Cap
Shift Lever Knob Cover

Bulb
Grooved Pin
Spring Plate
Indicator Light
Wire
Shift Lever Subassembly
Shift Lever Plate
Spring
Shift Lock
Control Computer
Control Shaft
MP grease
L Precoated part
Collar
D09906
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AX18

AX05L03
REMOVAL
1.
2.
(a)
(b)

REMOVE SHIFT LEVER ASSEMBLY
Disconnect the 3 connectors and wire harness.
(c)
Remove the 4 bolts and floor shift assembly.

D02081
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AX19

AX0C504
DISASSEMBLY
1.
(a)
(b)
(c)
2
1

Remove the O/D main switch connector from the shift lever plate.
Disengage the secondary locking device.
Release the locking lug of the terminals 2 and 4, and pull
the terminals out from the rear.
A00451
2.
NOTICE:
Pay attention not to put unnatural load onto O/D main
(b) Remove the shift lever knob cover.
(c) Remove the shift lever button and spring.
3.
4.
REMOVE CAP AND BULB FROM INDICATOR LIGHT
WIRE
5.
REMOVE INDICATOR HOUSING
Remove the screws and an indicator housing.
6.
(a)
(b)
(c)
(d)
(e)
DISASSEMBLE INDICATOR HOUSING

Remove the position indicator lower housing.
Remove the shift lock release button and spring.
Remove the position indicator slide cover.
D08694
7.
8.
REMOVE SPRING PLATE
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AX20
9.
(a)
(b)

Using a screwdriver and a hammer, remove the control
shaft.
F00683
10.
(a)

Measure the distance A between the lower edge of the
shift lever knob sleeve and the upper edge of the shift lever subassembly.
D04313
(b) Using a hammer, remove the grooved pin.

NOTICE:
When pressing down the grooved pin, if doing it at the
place other than the notch, there may be fear of damaging
the shift lever subassembly.
(c) Remove the detent rod and spring.
(d) Remove the shift lever knob sleeve from the detent rod.
F00687
11. REMOVE COLLARS

Using a screwdriver and a hammer, remove the 4 collars.
F00685
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AX21

AX0C604
REASSEMBLY
: Apply MP Grease
1.
2.
INSTALL COLLARS
INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT
ROD
3.
(a)

Apply MP grease on the compression spring, the detent
rod and the shift lever subassembly.
Install the spring and the detent rod to shift lever subassembly.
(b)
F00686
(c)
Place the shift lever subassembly as shown in the illustration.
F00684
Correct
(d) Insert the grooved pin in the detent rod pin hole.
NOTICE:
S
Assemble the grooved pin to ensure that it fits into the
guide hole of the shift lever subassembly in parallel.
S
of the detent rod.
Wrong
F00688
(e)
Meet the grooved pin with the notch of the guide hole.
F00689
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AX22
(f)
Press the pin with a hammer.

A: 10.0 10.4 mm (0.39 0.41 in.)
NOTICE:
When pressing in the grooved pin, if doing it at the place
other than the notch, the shift lever subassembly might be
damaged.
4.
CHECK DETENT ROD OPERATION
Shift Lever
Subassembly
A
Detent Rod
A00452
Grooved Pin
F01188
5.
INSTALL SHIFT LEVER KNOB SLEEVE DETENT ROD
Drive the shift lever knob sleeve to the distance A measured before removal.
D04313
6.
(a)
: Apply MP Grease

Apply MP grease.
F00690
(b)
Using a brass bar and a hammer, install the control shaft

and the shift lever subassembly to the shift lever plate.
NOTICE:
Take care not to install them in the wrong direction of the
shift lever subassembly.
7.
INSTALL SPRING PLATE
F00691
8.
Install the shift control control computer and 2 screws.
NOTICE:
Install the grooved pin into the groove of the shift lock unit
F00692
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AX23
9.
ASSEMBLE INDICATOR HOUSING
(a) Install the position indicator plate.
(b) Install the position indicator slide cover.
(c) Install the spring and shift lock release button.
(d) Install the position indicator lower housing.
(e) Install the pattern select switch.
NOTICE:
Do not make indicator housing dirty with MP grease.
10. INSTALL INDICATOR HOUSING
Install the screws and an indicator housing.
11. INSTALL CAP AND BULB TO INDICATOR LIGHT WIRE
(b) Install the spring and shift lever button.
HINT:
Apply MP grease to shift lever knob button.
(d) Install the shift lever subassembly and 2 screws.
HINT:
Sealant:
242 or equivalent
NOTICE:
(e) Install the O/D main switch wire harness securely to hung
on the hook of the shift lever subassembly.
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AX24

AX02Y08
INSTALLATION

release button in.
Shift normally
D02013

AX18).
HINT:
After installation, adjust shift lever ranges (See page DI62)
and inspect shift lever operation.
S
R N D 2
P R, 2 L, N R P
S
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AX25

AX05N02
COMPONENTS
12 (120, 9)
Clip
Rear Console Box

Shift Control Cable
Shift Lever
Assembly
Cap
Parking Brake Cover

D02091
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AX26
Shift Lever Button

Spring
Shift Lever Knob
Position Indicator Plate
Position Indicator
Upper Housing
L
O/D Main
Switch
Position Indicator
Slide Cover
Bulb
Detent Rod
Shift Lever Knob

Cover
Indicator Light Wire

Spring
Stopper Pin
Control Shaft
Detent Roller
Holder
Spring
Shift Lever SubAssembly
Shift Lock Plate

Spring
Shift Lever
Plate
Collar
x4
MP grease
L Precoated part
D09907
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AX27

AX05O02
REMOVAL
1.
2.
(a)
(b)

REMOVE FLOOR SHIFT ASSEMBLY
(c)
Remove the 4 bolts and shift lever assembly.

D02093
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AX28

AX11001
DISASSEMBLY
1.
(a)
2
1
A00451

Remove O/D main switch connector from the shift lever
plate.
(b) Disengage the secondary locking device.
(c) Disengage the locking lug of the terminals 2 and 4, and
pull the terminals out from the rear.
2.
NOTICE:
Pay attention not to apply unnatural load onto O/D main
(b) Remove the Shift lever knob cover.
(c) Remove the Shift lever button and spring.
3.
4.
REMOVE BULB FROM INDICATOR LIGHT WIRE
5.
REMOVE INDICATOR HOUSING SUBASSEMBLY
6.
(a)
(b)
(c)
DISASSEMBLE INDICATOR HOUSING SUBASSEMBLY

Remove the position indicator side cover.
D02094
7.
D09908
8.
REMOVE STOPPER PIN, DETENT ROD AND SPRING
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AX29
9.
(a)
(b)

Using an extension bar and hammer, remove the control
shaft.
10.
(a)
(b)

Remove the Detent roller holder.
Remove the Compression spring.
D02095
D02096
11. REMOVE COLLARS

Using an extension bar and hammer, remove the 4 collars.
D02040
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AX30

AX05Q02
REASSEMBLY
: Apply MP Grease
1.
INSTALL COLLARS
2.
(a)

Apply the MP grease to the detent roller holder, compression spring and shift lever subassembly.
Install the compression spring to the detent roller holder.
Install the detent roller holder with the compression spring
to the shift lever subassembly.
(b)
(c)
D02096
3.
(a)
: Apply MP Grease
D02041

Apply the MP grease to the control shaft and shift lever
subassembly.
(b) Using an extension bar and hammer, install the control
shaft and shift lever subassembly to the shift lever plate.
4.
INSTALL SPRING, DETENT ROD AND STOPPER PIN
(a) Apply the MP grease to the detent rod and stopper pin.
(b) Install the compression spring and detent rod to the shift
lever subassembly.
(c) Insert the stopper pin in the stopper pin hole.
NOTICE:
against the detent rod.
5.
Install the shift lock control computer with 3 screws.
6.
CHECK SHIFT LEVER OPERATION
7.
ASSEMBLE INDICATOR HOUSING SUBASSEMBLY
(a) Install the pattern select switch.
(b) Install the position indicator plate.
(c) Install the position indicator slide plate.
8.
INSTALL INDICATOR HOUSING SUBASSEMBLY
9.
INSTALL BULB TO INDICATOR LIGHT WIRE
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AX31

HINT:
Apply MP grease to the shift lever knob button.
(b) Install the shift lever button and spring.
(d) Install the shift lever knob subassembly and 2 screws.
HINT:
Sealant:
242 or equivalent
NOTICE:
(e) Install the O/D main switch wire harness securely and
hang it on the hook of the shift lever subassembly.
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AX32

AX05R03
INSTALLATION

release button in.
Shift normally
D02013

AX27).
HINT:
After installation, adjust shift lever ranges (See page DI62)
and inspect shift lever operation.
S
R N D 2
P R, 2 L, N R P
S
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AX33

AX06402
COMPONENTS
Battery
Air Cleaner Assembly
RH Drive Shaft
87 (890, 64)
64 (650, 47)
64 (650, 47)
Torque Converter Clutch
18 (185, 13)
41 (420, 30)
Ground Cable
46 (470, 34)
x6
52 (530, 38)
87 (890, 64)
Hole Plug
z Snap Ring
64 (650, 47)
LH Drive Shaft
225 (2,305, 167)
Control Cable
z Cotter Pin
Starter
Clip
Plug for Hydraulic Test
39 (400, 29)
Lock Nut Cap

12 (120, 9)
10 (100, 7)
39 (400, 29)
Exhaust Front Pipe
127 (1,300, 94)

43 (440, 32)
Suction Hose (RHD)
Front Center Member
73 (740, 54)
Engine Under Cover LH
x5
z
Grommet
62 (630, 46)
72 (740, 53)
Grommet
Front Center Member
Protector
73 (740, 54)
x5
z Nonreusable part
39 (400, 29)
D09909
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AX34

AX11101
REMOVAL
1.
2.
REMOVE BATTERY
3.
(a)
(b)
REMOVE STARTER
Remove the nut and disconnect the connector.
Remove the 2 bolts, bracket and starter.
4.
D09912
5.
REMOVE 4 UPPER SIDE TRANSAXLE MOUNTING

BOLTS
6.
7.

REMOVE ENGINE UNDER COVERS
D09913
D02517
8.
REMOVE LH SIDE ENGINE MOUNTING
Remove the 5 bolts, nut and LH engine mounting.
Torque:
9.
SA3)
A
A
A
D02518
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AX35
10. DISCONNECT SHIFT CONTROL CABLE

Remove the nut, clip and disconnect the shift control cable.
11. DISCONNECT NEUTRAL START SWITCH CONNECTOR AND SOLENOID CONNECTOR
12. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
D09914
13.
(a)
(b)
D09915
HINT:
Replace the used nuts with new ones.
(c) Remove the 2 bolts, nuts and exhaust front pipe with 2
gaskets.
HINT:
Replace the used nuts with new ones.
(d) Remove the 2 gaskets from the exhaust front pipe.
HINT:
Replace the used gaskets with new ones.
14.
(a)
A
C
(b)
REMOVE EXHAUST FRONT PIPE

Disconnect the oxygen sensor connector.
Remove the 2 nuts from the exhaust manifold.
B
D02064
15.
REMOVE FRONT CENTER MEMBER

RHD:
Remove the nut and disconnect the suction hose from the
front center member.
Remove the 9 bolts, 3 grommets, front center member
protector and front center member.
Torque:
C: 72 Nm (740 kgfcm, 53 ftlbf)
DISCONNECT OIL COOLER HOSES
D02523
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AX36
16.
SUPPORT TRANSAXLE
17.
REMOVE ENGINE REAR MOUNTING BOLT

D02524
D10022

Remove the 3 bolts and engine rear mounting bracket.
D02044
19.
(a)
D10023
REMOVE TRANSAXLE
Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley bolt by a wrench.
HINT:
First, install the gray bolt. Then install 5 black bolts.
(b) Remove the 4 bolts.
(c) Lower the left side of the engine and remove the transaxle
from the engine.
HINT:
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AX37

AX06602
INSTALLATION
D02529
1.
CHECK TORQUE CONVERTER INSTALLATION
Using a scale and a straight edge, measure the distance from
the installation surface to the front surface of the transaxle
housing.
Correct distance: More than 12.75 mm (0.502 in.)
2.
TRANSAXLE INSTALLATION
AX34).
HINT:
S
After installation, adjust the shift control cable and neutral
start switch (See page DI62).
S
Fill ATF and check fluid level (See page DI62).
S
Perform the test drive of the vehicle (See page DI62).
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AX38
TORQUE CONVERTER AND DRIVE

PLATE
SST
AX06702
INSPECTION
1.
(a)
AT0953
Hold
Lock
Turn
INSPECT ONEWAY CLUTCH

Install SST into the inner race of the oneway clutch.
SST 0935032014 (0935132010)
(b) Install SST so that it fits in the notch of the converter hub
and outer race of the oneway clutch.
SST 0935032014 (0935132020)
(c) With the torque converter set up on its side, check that the
clutch locks when it is turned counterclockwise, and rotates smoothly clockwise.
If necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.
Free
AT3306
2.
MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR
(a) Set up a dial indicator and measure the drive plate runout.
(b) Check the damage of the ring gear.
If the runout is not within the specification or ring gear is damaged, replace the drive plate.
Torque: 98 Nm (1,000 kgfcm 72 ftlbf)
D02544
D02545
3.
MEASURE TORQUE CONVERTER SLEEVE RUNOUT
Temporarily mount the torque converter to the drive plate. Set
up a dial indicator and measure the torque converter sleeve
runout.
If the runout is not within the specification, try to correct by reorienting the installation of the converter.
HINT:
Mark the position of the converter to ensure the correct installation.
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SUSPENSION AND AXLE

FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . .
FRONT SHOCK ABSORBER . . . . . . . . . . . . . .
SA1
SA13
REFER TO FOLLOWING REPAIR MANUALS:

Manual Name
Pub. No.
RM599E

Supplement (Aug., 1999)
RM698E
NOTE: The above pages contain only the points which differ
from the above listed manuals.
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SA1
SUSPENSION AND AXLE
FRONT DRIVE SHAFT
FRONT DRIVE SHAFT

SA10903
COMPONENTS
1AZFSE
Center Bearing Bracket
1ZZFE, 1AZFSE
RH Drive Shaft
64 (650, 47)
1ZZFE
Center Bearing Bracket
3ZZFE
RH Drive Shaft
64 (650, 47)
z Snap Ring
z Snap Ring
1ZZFE, 3ZZFE
LH Drive Shaft
1AZFSE
LH Drive Shaft
z Cotter Pin
49 (500, 36)
Tie Rod End
8.0 (82, 71 in.lbf)
ABS Speed Sensor

z Cotter Pin
Lower Suspension Arm

216 (2,200, 159)
Lock Cap
127 (1,300, 94)

z Nonreusable part
F12734
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SA2
SUSPENSION AND AXLE
FRONT DRIVE SHAFT
Outboard Joint Shaft
z Boot
Dynamic Damper
z Dynamic Damper Clamp
z Boot Clamp
z Boot
z Snap Ring
Tripod
3ZZFE
Straight Pin
z Snap Ring
z Snap Ring
RH Inboard Joint Shaft

z Snap Ring
1ZZFE
Bearing Case
z Dust Cover
Bearing
Tripod
LH
RH Inboard Joint Shaft
1AZFSE
z Dust Cover
z Dust Cover
Straight
Pin
Inboard Joint Shaft

Bearing Case
z Nonreusable part
F02723
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SA3
SUSPENSION AND AXLE
FRONT DRIVE SHAFT

SA10A03
REMOVAL
SST
FA1535
NOTICE:
S
The hub bearing could be damaged if it is subjected
to the vehicle weight, such as when moving the vehicle with the drive shaft removed.
Therefore, if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with
the SST.
SST 0960816042 (0960802021, 0960802041)
S
w/ ABS:
After disconnecting the drive shaft from the axle hub,
work carefully so as not to damage the ABS speed
sensor rotor serration on the drive shaft.
1.
REMOVE FRONT WHEEL
2.
DRAIN OUT GEAR OIL (M/T) OR ATF (A/T)
3.
w/ ABS:
REMOVE BOLT AND ABS SPEED SENSOR
4.
(a)
(b)
5.
6.
F02688
REMOVE DRIVE SHAFT LOCK NUT

Remove the cotter pin and lock cap.
While applying the brakes, remove the nut.
DISCONNECT TIE ROD END FROM STEERING
KNUCKLE (See Pub. No. RM599E on page SA 36)
DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM (See Pub. No. RM599E on page
SA36)
7.
(a)
DISCONNECT DRIVE SHAFT FROM AXLE HUB

Using a plastic hammer, disconnect the drive shaft from
the axle hub.
NOTICE:
Cover the drive shaft boot and ABS speed sensor rotor with
cloth to protect it from being damaged.
(b) Push the front axle hub toward the outside of the vehicle
to separate the drive shaft from the axle hub.
F02721
8.
RH drive shaft of 1ZZFE and 1AZFSE engine:

REMOVE DRIVE SHAFT
Remove the 2 bolts and pull out the drive shaft together with the
center bearing bracket.
HINT:
At the time of installation, coat gear oil to the inboard joint shaft
and differential case sliding surface.
F02724
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SA4
SUSPENSION AND AXLE
9.
SST
(a)
SST
F02725
FRONT DRIVE SHAFT
3ZZFE engine:
REMOVE DRIVE SHAFT
Using SST, remove the drive shaft.
SST 0952001010, 0952024010 (0952032040)
(b)
HINT:
S
Apply gear oil to the inboard joint shaft and differential
case sliding surface.
S
Before installing the drive shaft, set the snap ring with its
opening side facing downward.
S
Whether inboard joint shaft is in contact with pinion shaft
or not can be known from the sound or feeling.
S
After installation, check that there is 2 3 mm (0.08 0.12
in.) of play in the axial direction.
S
After installation, check that the drive shaft cannot be removed by hand.
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SA5
SUSPENSION AND AXLE
FRONT DRIVE SHAFT

SA10B03
DISASSEMBLY
1.
(a)
N00191
CHECK DRIVE SHAFT

Check to see that there is no obvious play in the outboard
joint.
(b) Check to see that the inboard joint slides smoothly in the
thrust direction.
(c) Check to see that there is no obvious play in the radial
direction of the inboard joint.
(d) Check the boots for damage.
2.
REMOVE INBOARD AND OUTBOARD JOINT BOOT
CLAMPS
Using a side cutter, cut the 4 boots clamps and remove them.
3.
(a)
Matchmarks
FA1615
Matchmarks
SA1443
REMOVE INBOARD JOINT SHAFT

Place matchmarks on the tripod, inboard and outboard
joint shafts.
NOTICE:
Do not punch the marks.
(b) Remove the inboard joint shaft from the outboard joint
shaft.
4.
REMOVE TRIPOD
(a) Using a snap ring expander, remove the snap ring.
(b) Using a snap ring expander, temporarily slide the snap
ring toward the outboard joint shaft side.
(c) Place matchmarks on the outboard joint shaft and tripod.

NOTICE:
Do not punch the marks.
(d) Using a brass bar and hammer, remove the tripod from
the drive shaft.
NOTICE:
Do not tap the roller.
(e) Using a snap ring expander, remove the snap ring.
5.
REMOVE INBOARD JOINT BOOT
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SA6
SUSPENSION AND AXLE
FRONT DRIVE SHAFT
6.
(a)
REMOVE DYNAMIC DAMPER

Using a side cutter, cut the dynamic damper clamp and remove it.
(b) Remove the dynamic damper.
7.
REMOVE OUTBOARD JOINT BOOT
NOTICE:
Do not disassemble the outboard joint.
SST
8.
(a)
REMOVE DUST COVER

RH drive shaft of 3ZZFE engine and LH drive shaft:
Using SST and a press, remove the dust cover from the
inboard joint shaft.
SST 0995000020
(b)

Using a press, remove the dust cover from the inboard
joint shaft.
9.

DISASSEMBLE INBOARD JOINT SHAFT
Using a press, remove the bearing case.
Using a pin punch and hammer, remove the straight pin
from the bearing case.
R09716
SA1446
(a)
(b)
(c)
Z18045
(d)
SST
(e)
Using SST and a press, remove the dust cover.

SST 0995000020
Using a snap ring expander, remove the snap ring.
Z18046
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SA7
SUSPENSION AND AXLE
(f)
FRONT DRIVE SHAFT
Using a press, remove the bearing.
SA1451
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SA8
SUSPENSION AND AXLE
FRONT DRIVE SHAFT

SA10C03
REASSEMBLY
1.
(a)

ASSEMBLE INBOARD JOINT SHAFT
Using a pin punch and hammer, install the straight pin into
the bearing case.
SA1453
(b)
SST
(c)
Using SST and a press, install a new bearing into the

bearing case.
SST 0995060010 (0995100640), 0995070010
(0995107150)
Using a screwdriver, install a new snap ring.
W00880
(d)
(e)
SST
Using SST and a press, install the bearing case assembly

to the inboard joint shaft.
SST 0971030021 (0971003141)
Using a snap ring expander, install a new snap ring.
SA1456
(f)
Using SST, an extension bar and press, install a new dust

cover.
SST 0950635010
2.
(a)
INSTALL NEW DUST COVER

RH drive shaft of 3ZZFE engine:
Using a steel plate and press, install a new dust cover until
the distance from the tip of center drive shaft to the dust
cover reaches the specification, as shown in the illustration.
SST
FA1971
83 84 mm
(3.27 3.31 in.)
SA1459
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SA9
SUSPENSION AND AXLE
FRONT DRIVE SHAFT
(b)

Using a steel plate and press, install a new dust cover until
the distance from the tip of center drive shaft to the dust
cover reaches the specification, as shown in the illustration.
A:
1ZZFE Engine M/T:
86 87 mm (3.39 3.43 in.)
1ZZFE Engine A/T:
83 84 mm (3.27 3.31 in.)
1AZFSE Engine:
87 88 mm (3.43 3.46 in.)
3.
TEMPORARILY INSTALL NEW OUTBOARD AND INBOARD JOINT BOOTS WITH NEW BOOT CLAMPS
F02277
Vinyl Tape
HINT:
S
W01994
Before installing the boots (and dynamic damper), wrap

the spline of the outboard joint shaft with vinyl tape to prevent them from being damaged.
S
Before installing the boots (and dynamic damper), place
new clamps to each of them and then install boots to drive
shaft.
(a) Temporarily install a new outboard joint boot with 2
clamps to the drive shaft.
(b) w/ Dynamic damper:
Temporarily install the dynamic damper with clamp to the
drive shaft.
(c) Temporarily install a new inboard joint boot with 2 clamps
to the drive shaft.
4.
INSTALL TRIPOD
(a) Using a snap ring expander, install a new snap ring.
(b) Place the beveled side of the tripod axial spline toward the
outboard joint.
(c) Align the matchmarks placed before removal.
(d) Using a brass bar and hammer, tap in the tripod to the
drive shaft.
NOTICE:
Do not tap the roller.
(e) Using a snap ring expander, install a new snap ring.
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SA10
SUSPENSION AND AXLE
FRONT DRIVE SHAFT
5.
INSTALL BOOT TO OUTBOARD JOINT
Before assembling the boot, pack the outboard joint shaft and
boot with grease in the boot kit.
Grease capacity: (Color = Black)
85 105 g (3.00 3.70 oz.)
6.
INSTALL INBOARD JOINT SHAFT TO OUTBOARD
JOINT SHAFT
(a) Pack the inboard joint shaft and boot with grease in the
boot kit.
Grease capacity: (Color = Yellow)
1ZZFE engine:
140 150 g (4.94 5.29 oz.)
3ZZFE engine:
125.5 135.5 g (4.43 4.78 oz.)
1AZFSE engine:
120 130 g (4.23 4.59 oz.)
(b) Align the matchmarks placed before removal.
(c) Install the inboard joint shaft to the outboard joint shaft.
(d) Temporarily install the boot to the inboard joint shaft.
RH Drive shaft of 1ZZFE and 1AZFSE
7.
(a)
(b)
3ZZFE
F02726
ASSEMBLE BOOT CLAMPS TO BOTH BOOTS

Make sure that the 2 boots are on the shaft groove.
Make sure that the 2 boots are not stretched or contracted
when the drive shaft is at standard length.
Drive shaft standard length:
1ZZFE engine M/T:
RH
943.60 1.0 mm (37.15 0.039 in.)
LH
657.90 0.8 mm (25.90 0.032 in.)
1ZZFE engine A/T:

RH
943.60 1.0 mm (37.15 0.039 in.)
LH
653.20 0.8 mm (25.72 0.032 in.)
3ZZFE engine:
RH
944.70 0.8 mm (37.19 0.032 in.)
LH
655.70 0.8 mm (25.82 0.032 in.)
1AZFSE engine:
(c)
RH
922.65 1.0 mm (36.32 0.039 in.)
LH
650.85 0.7 mm (25.62 0.028 in.)
Secure the clamps onto the boot.
(d)
Place SST onto the clamps.

SST 0952124010
(e) Tighten the SST so that the clamps are pinched.
NOTICE:
Do not overtighten the SST.
(f)
Using SST, adjust the clearance of the clamps.
SST 0924000020
Clearance: 1.9 mm (0.075 in.) or less
SST
R10353
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SA11
SUSPENSION AND AXLE
8.
(a)
(b)
(c)
FRONT DRIVE SHAFT
RH drive shaft of 3ZZFE engine:

ASSEMBLE DAMPER CLAMP
Make sure that the dynamic damper is on the shaft
groove.
Set the distance, as described below.
Distance: 432.1 2.0 mm (17.012 0.079 in.)
Secure the clamp onto the damper.
R03119
(d)
SST
F02727
Place SST onto the clamps.

SST 0952124010
(e) Tighten the SST so that the clamps are pinched.
NOTICE:
Do not overtighten the SST.
(f)
Using SST, adjust the clearance of the clamps.
SST 0924000020
Clearance: 1.9 mm (0.075 in.) or less
9.
CHECK DRIVE SHAFT (See page SA5)
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SA12
SUSPENSION AND AXLE
FRONT DRIVE SHAFT

SA02Z04
INSTALLATION
Installation is in the reverse order of removal (See page SA3).
HINT:
After installation, check the ABS speed sensor signal and front wheel alignment (See Pub. No. RM599E on
page SA4).
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SA13
SUSPENSION AND AXLE
FRONT SHOCK ABSORBER

SA10J06
COMPONENTS
Cap
z 47 (475, 34)
80 (820, 59)
Suspension Support
Dust Seal
Spring Upper Seat
Upper Insulator
Coil Spring
Shock Absorber
with Coil Spring
Spring Bumper
ABS Speed Sensor
Wire Harness
Lower Insulator
5.5 (55, 48 in.lbf)
255 (2,600, 188)
29 (300, 22)
Shock Absorber
Flexible Hose

z Nonreusable part
F12735
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SA14
SUSPENSION AND AXLE

SA10K03
REMOVAL
1.
REMOVE FRONT WHEEL

2.
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
CLAMPS FROM SHOCK ABSORBER
Remove the bolt and disconnect the ABS speed sensor wire
harness clamps.
3.
DISCONNECT FLEXIBLE HOSE
Remove the bolt and disconnect the flexible hose from the
shock absorber bracket.
4.
REMOVE SHOCK ABSORBER WITH COIL SPRING
(a) Loosen the 2 nuts on the lower side of shock absorber.
HINT:
Do not remove the 2 bolts.
(b)
(c)
Remove the 3 nuts.

Remove the 2 nuts and bolts on the lower side of shock
absorber.
HINT:
At the time of installation, coat the nuts thread with engine oil.
(d) Remove the shock absorber with coil spring.
F12736
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SA15
SUSPENSION AND AXLE

SA10P05
INSTALLATION
Installation is in the reverse order of removal (See page SA14).
HINT:
After installation, check the front wheel alignment (See Pub. No. RM599E on page SA4).
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BRAKE
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . .
BR1

Manual Name
Pub. No.
RM599E

RM698E
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BR1
BRAKE
Stop Light Switch
BRAKE PEDAL
BRAKE PEDAL
BR0KI06
ONVEHICLE INSPECTION
1.
Push Rod
Pedal Height
R02868
CHECK PEDAL HEIGHT

Pedal height from asphalt sheet:
(LHD)
147.0 157.0 mm (5.787 6.181 in.)
(RHD)
149.5 159.5 mm (5.886 6.280 in.)
If the pedal height is incorrect, adjust it.
2.
RHD:
IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
(f)
Install the stop light switch.
(g) Push the brake pedal in 5 15 mm (0.20 0.59 in.), turn
the stop light switch and lock the nut in the position where
the stop light goes off.
(h) Connect the connector to the stop light switch.
(i)
After installation, push the brake pedal in 5 15 mm (0.20
0.59 in.), check that stop light lights up.
(j)
After adjusting the pedal height, check the pedal freeplay.
3.
(a)
Pedal Freeplay
R00935
(b)
CHECK PEDAL FREEPLAY

Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
Push in the pedal by hand until the resistance begins to
be felt, then measure the distance.
Pedal freeplay: 1 6 mm (0.04 0.24 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 3 mm (0.04 0.12 in.)
at the pedal.
S
If incorrect, check the stop light switch clearance.
S
If the clearance is OK, then troubleshoot the brake
system.
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BR2
BRAKE
Pedal Reserve Distance
R00934
BRAKE PEDAL
4.
CHECK PEDAL RESERVE DISTANCE
Release the parking brake. With the engine running, depress
the pedal and measure the pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
LHD Gasoline engine (w/o ABS)
More than 70 mm (2.76 in.)
LHD others
RHD Gasoline engine (w/o ABS)
RHD others
If the reserve distance is incorrect, troubleshoot the brake system.
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STEERING
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING FLUID . . . . . . . . . . . . . . .
TILT STEERING COLUMN . . . . . . . . . . . . . . . .
POWER STEERING VANE PUMP
SR1
SR2
SR6
(1ZZFE, 3ZZFE) . . . . . . . . . . . . . . . . . . . . .
(1AZFSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SR8
SR19

Manual Name
Pub. No.
RM599E

RM698E
http://vnx.su
http://vnx.su
SR1
STEERING
DRIVE BELT
DRIVE BELT
SR08H06
INSPECTION
P06717
INSPECT DRIVE BELT

Visually check the drive belt for excessive wear, frayed cords,
etc.
If any defect has been found, replace the drive belt.
HINT:
S
Cracks on the rib side of a belt are considered acceptable.
If the missing chunks from the ribs are found on the drive
belt, it should be replaced.
S
S
CORRECT
WRONG
After installing a drive belt, check that it fits properly in the

ribbed grooves.
Check with your hand to confirm that the drive belt has not
slipped out of the groove on the bottom of the pulley.
WRONG
F01336
http://vnx.su
SR2
STEERING
POWER STEERING FLUID

SR08I07
BLEEDING
1.
2.
CHECK FLUID LEVEL (See page SR3)

JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3.
TURN STEERING WHEEL
With the engine stopped, turn the steering wheel slowly from
lock to lock several times.
4.
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 steering wheel to left or
right full lock position and keep it there for 23 seconds,
then turn the steering wheel to the opposite full lock position and keep it there for 23 seconds.
(b) Repeat (a) several times.
7.
STOP ENGINE
Normal
8.
CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system.
9.
CHECK FLUID LEVEL (See page SR3)
Abnormal
R11741
http://vnx.su
SR3
STEERING

SR08J05
INSPECTION
HOT
COLD
R11740
Normal
1.
(a)
(b)
CHECK FLUID LEVEL

Keep the vehicle level.
With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir. 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 temperature: 80C (176F)
(e) Check for foaming or emulsification.

If there is foaming or emulsification, bleed power steering system (See page SR2).
Abnormal
R11741
(f)
5 mm (0.20 in.) or less
Engine Idling
Engine Stopped
R11786
With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system (See page
SR2).
(i)
Check the fluid level.
http://vnx.su
SR4
STEERING
2.
(a)
CHECK STEERING FLUID PRESSURE

Disconnect the pressure feed tube from the PS vane
pump.
(1ZZFE, 3ZZFE Engines: See page SR10)
(1AZFSE Engine: See page SR21)
(b) Connect SST, as shown in the illustration below.
SST 0964010010 (0964101010, 0964101030,
0964101060)
NOTICE:
Check that the valve of the SST is in the open position.
1ZZFE, 3ZZFE Engines:
SST
1AZFSE Engine:
Pressure Feed Tube
Attachment
SST
Attachment
IN
OUT
IN
OUT
Pressure
Feed Tube
PS Vane Pump
Attachment
PS Vane Pump
Attachment
F13065
(c)
(d)
(e)
Bleed the power steering system (See page SR2).

Start the engine and run it at idle.
Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 C (176 F)
http://vnx.su
SR5
STEERING
(f)
Oil
reservoir
PS Gear
Closed
PS Vane
Pump
SST
Z15498
Oil
reservoir
PS Gear
Open
PS Vane
Pump
SST
With the engine idling, close the valve of the SST and observe the reading on the SST.
Minimum fluid pressure:
8,300 kPa (85 kgf/cm2, 1209 psi)
1AZFSE Engine:
8,800 kPa (90 kgf/cm2, 1280 psi)
NOTICE:
S
Do not keep the valve closed for more than 10 seconds.
S
Do not let the fluid temperature become too high.
(g)
(h)
With the engine idling, open the valve fully.

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
NOTICE:
Do not turn the steering wheel.
Z15499
(i)
Oil
reservoir
Lock Position
PS Gear
Open
PS Vane
Pump
SST
Z15500
With the engine idling and valve fully opened, turn the
steering wheel to full lock.
Minimum fluid pressure:
8,300 kPa (85 kgf/cm2, 1209 psi)
1AZFSE Engine:
8,800 kPa (90 kgf/cm2, 1280 psi)
NOTICE:
S
Do not maintain lock position for more than 10 seconds.
S
Do not let the fluid temperature become too high.
(j)
Disconnect the SST.
SST 0964010010 (0964101010, 0964101030,
0964101060)
(k) Connect the pressure feed tube to the PS vane pump.
(1ZZFE, 3ZZFE Engines: See page SR18)
(1AZFSE Engine: See page SR29)
(l)
Bleed the power steering system (See page SR2).
http://vnx.su
SR6
STEERING
TILT STEERING COLUMN

SR0IB02
COMPONENTS
HINT:
If the steering column assembly (w/ VSC) is removed or replaced, calibrate the steering angle sensor zero
point (See page DI171).
Instrument Cluster Finish Panel
Steering Wheel Pad

50 (510, 37)
Column Upper Cover

Torx Screw
8.8 (90, 78 in.lbf)
Steering Wheel
Torx Screw
8.8 (90, 78 in.lbf)
Combination Switch
(w/ Spiral Cable)
25.5 (260, 19)
Column Lower Cover

35 (360, 26)
25.5 (260, 19)
Steering Column Assembly
Clamp
Lower Instrument Finish Panel
w/ VSC:
Hood Lock Control Cable
F13066
http://vnx.su
SR7
STEERING
w/ Engine Immobiliser System:
w/ Shift Lock System:
Transponder Key
Computer Assembly
Key Inter Lock Solenoid
Transponder Key
Computer Case
Key Cylinder
Column Upper Bracket

Key Unlock
Warning Switch
Column Upper Clamp
Ignition Switch
z Taperedhead Bolt
w/ VSC:
z Nonreusable part
F13067
http://vnx.su
SR8
STEERING
POWER STEERING VANE PUMP (1ZZFE, 3ZZFE)

SR0YO05
COMPONENTS
Pressure Feed Tube
44 (450, 33)
*37 (375, 27)
7.8 (80, 69 in.lbf)
Oil Pressure Switch Connector

Suction Hose
PS Vane Pump Assembly

Clip
37 (370, 27)
Drive Belt
x5
* For use with SST
F13062
http://vnx.su
SR9
STEERING
Pressure Port Union

69 (700, 51)
z ORing
Flow Control Valve
Oil Pressure Switch
21 (210, 15)
Spring
Suction Port Union
z ORing
12 (120, 9)
44 (440, 32)
Heat Insulator
z Oil Seal
Front Housing
Pump Rear Bracket

22 (220, 16)
Rear Housing
Vane Pump Shaft with
Vane Pump Pulley
z Snap Ring
22 (220, 16)
Vane Pump Rotor

Side Plate
z ORing
z ORing
x 10
22 (220, 16)
Vane Plate
Cam Ring
z Nonreusable part
Power steering fluid
F13063
http://vnx.su
SR10
STEERING

SR0YP02
REMOVAL
1.
REMOVE ENGINE UNDER COVER RH
Remove the 5 bolts and engine under cover RH.
2.
REMOVE DRIVE BELT
Loosen the drive belt tension by turning the drive belt tensioner
arm clockwise, and remove the drive belt.
Drive Belt
Tensioner Arm
F08868
3.
DISCONNECT SUCTION HOSE
Remove the clip and disconnect the suction hose.
NOTICE:
Take care not to spill fluid on the drive belt.
4.
(a)
SST
(b)
DISCONNECT PRESSURE FEED TUBE

Using SST, disconnect the pressure feed tube.
SST 0902312700
Remove the bolt and disconnect the pressure feed tube
clamp.
F13068
5.
DISCONNECT OIL PRESSURE SWITCH CONNECTOR
6.
REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts, nuts and PS vane
pump assembly.
http://vnx.su
SR11
STEERING

SR0VS07
DISASSEMBLY
F13466
NOTICE:
When using a vise, do not overtighten it.
1.
MEASURE PS VANE PUMP ROTATING TORQUE
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
0.27 Nm (2.8 kgfcm, 2.4 in.lbf) or less
2.
REMOVE SUCTION PORT UNION
(a) Remove the bolt and suction port union.
(b) Remove the Oring from the suction port union.
3.
REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
(a) Remove the pressure port union, flow control valve and
spring.
(b) Remove the Oring from the pressure port union.
4.
REMOVE OIL PRESSURE SWITCH
NOTICE:
Be careful not to drop the oil pressure switch.
If the oil pressure switch is dropped or strongly damaged, replace it with a new one.
5.
REMOVE REAR HOUSING
(a) Remove the bolt, nut, heat insulator and pump rear bracket.
(b) Remove the 4 bolts and rear housing.
(c) Remove the Oring from the rear housing.
6.
REMOVE CAM RING, 10 VANE PLATES, VANE PUMP
ROTOR AND SIDE PLATE
(a) Remove the cam ring and 10 vane plates.
NOTICE:
Take care not to drop the vane plate.
(b) Using a screwdriver, remove the snap ring, vane pump rotor and side plate.
(c) Remove the 2 Orings from the side plate.
7.
REMOVE VANE PUMP SHAFT WITH VANE PUMP
PULLEY
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SR12
STEERING

SR0VT07
INSPECTION
1.
Bushing
Vane Pump Shaft
Front Housing
F09875
Thickness
MEASURE OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clearance.
Standard clearance:
0.021 0.043 mm (0.0008 0.0017 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2.
(a)
INSPECT VANE PUMP ROTOR AND VANE PLATES

Using a micrometer, measure the height, thickness and
length of the 10 vane plates.
Minimum height: 7.6 mm (0.299 in.)
Minimum thickness: 1.405 mm (0.0553 in.)
Minimum length: 11.993 mm (0.4722 in.)
(b)

the vane pump rotor groove and vane plate.
Height
Length
N00372
Feeler Gauge
R10282
http://vnx.su
SR13
STEERING
If it is more than the maximum, replace the vane plate and/or

vane pump rotor with the one having the same mark stamped
on the cam ring.
Inscribed mark: 0, 1, 2, 3, or 4
HINT:
There are 5 vane plate lengths corresponding to the following
vane pump rotor and cam ring marks:
Inscribed Mark
F08475
Vane pump rotor and

cam ring mark
Vane plate part

number
Vane plate length

mm (in.)
44345 02110
12.001 12.003
(0.47248 0.47256)
44345 02120
11.999 12.001
(0.47240 0.47248)
44345 02130
11.997 11.999
(0.47232 0.47240)
44345 02140
11.995 11.997
(0.47224 0.47232)
44345 02150
11.993 11.995
(0.47216 0.47224)
3.
(a)
INSPECT FLOW CONTROL VALVE

Coat the flow control valve with power steering fluid and
check that it falls smoothly into the valve hole of the front
housing by its own weight.
(b)
Check the flow control valve for leakage. Close one of the
holes and apply compressed air of 392 490 kPa (4 5
kgf/cm2, 57 71 psi) into the opposite side hole, and confirm that air does not come out from the end hole.
F08476
Compressed Air
F08804
If necessary, replace the flow control valve with the one having
the same letter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F
Inscribed Mark
Inscribed Mark
F08478
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SR14
STEERING
4.
INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 35.8 mm (1.409 in.)
If it is not within the specification, replace the spring.
Vernier Calipers
R08702
http://vnx.su
SR15
STEERING

SR0VU07
REPLACEMENT
NOTICE:
IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the bushing of the front housing.
Vinyl Tape
F08479
(b)
(c)
Coat a new oil seal lip with power steering fluid.

Using SST, press in the oil seal.
SST 0995060010 (0995100280),
0995070010 (0995107100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
SST
Oil Seal
F08480
http://vnx.su
SR16
STEERING

SR0VV07
REASSEMBLY
NOTICE:
1.
COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID (See page SR8)
2.
INSTALL VANE PUMP SHAFT WITH VANE PUMP
PULLEY
3.
(a)
INSTALL SIDE PLATE

Coat 2 new Orings with power steering fluid, and install
them to the side plate.
(b) Align the dent of the side plate with the dent of the front
housing, and install the side plate.
NOTICE:
Make sure that the side plate is installed facing in the correct direction.
F08482
4.
INSTALL CAM RING
Align the dent of the cam ring with the dent of the side plate, and
install the cam ring with the inscribed mark facing outward.
Inscribed Mark
F08483
5.
(a)
Inscribed Mark
Round End
INSTALL VANE PUMP ROTOR

Install the vane pump rotor with the inscribed mark facing
outward.
(b) Install a new snap ring to the vane pump shaft.
6.
INSTALL 10 VANE PLATES
Install the 10 vane plates with the round end facing outward.
F08484
7.
(a)
(b)
(c)
INSTALL REAR HOUSING

Coat a new Oring with power steering fluid, and install
it to the rear housing.
Align the straight pin of the rear housing with the dents of
the cam ring, side plate and front housing, and install the
rear housing with the 4 bolts.
Install the rear bracket and heat insulator with the bolt and
nut.
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SR17
STEERING
8.
9.
(a)
(b)
(c)
(d)
10.
(a)
(b)
11.
INSTALL OIL PRESSURE SWITCH

INSTALL SPRING, FLOW CONTROL VALVE AND
PRESSURE PORT UNION
Install the spring.
Install the flow control valve facing in the correct direction
(See page SR8).
it to the pressure port union.
Install the pressure port union.
INSTALL SUCTION PORT UNION
it to the suction port union.
Install the suction port union with the bolt.
MEASURE PS VANE PUMP ROTATING TORQUE (See
page SR11)
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SR18
STEERING

SR0YQ02
INSTALLATION
1.
INSTALL PS VANE PUMP ASSEMBLY
Install the PS vane pump assembly with the 2 pump assembly
set bolts and nuts.
2.
CONNECT OIL PRESSURE SWITCH CONNECTOR
NOTICE:
Be careful to prevent oil from being attached to the connector.
SST
3.
(a)
(b)
Fulcrum
Length
CONNECT PRESSURE FEED TUBE

Connect the pressure feed tube clamp with the bolt.
Using SST, connect the pressure feed tube.
SST 0902312700
HINT:
S
F13069
Use a torque wrench with a fulcrum length of 345 mm

(11.81 in).
S
This torque value is effective in case that SST is parallel
to a torque wrench.
4.
CONNECT SUCTION HOSE
Connect the suction hose with the clip.
5.
INSTALL DRIVE BELT
arm clockwise, and install the drive belt.
Drive Belt
Tensioner Arm
F08868
6.
INSTALL ENGINE UNDER COVER RH
Install the engine under cover RH with 5 bolts.
7.
BLEED POWER STEERING SYSTEM
(See page SR2)
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SR19
STEERING
POWER STEERING VANE PUMP (1AZFSE)

SR19E02
COMPONENTS
Union Bolt
52 (530, 38)
z Gasket
Oil Pressure Switch
Suction Hose
Pressure Feed Tube
Clip
PS Vane Pump Assembly
50 (510, 37)
Drive Belt
x5
z Nonreusable part
* For use with SST
F13064
http://vnx.su
SR20
STEERING
Pressure Port Union

69 (700, 51)
z ORing
Flow Control Valve
Oil Pressure Switch

21 (210, 15)
Spring
z ORing
Suction Port Union

12 (120, 9)
Vane Pump Shaft with

Vane Pump Pulley
z Oil Seal
Front Housing
22 (220, 16)
Rear Housing
z Snap Ring
Vane Pump Rotor
Side Plate
z ORing
z ORing
X10
Vane Plate
Cam Ring

z Nonreusable part
F13606
http://vnx.su
SR21
STEERING

SR1C801
REMOVAL
1.
Remove the 5 bolts and engine under cover RH.
2.
REMOVE DRIVE BELT
Using SST, loosen the drive belt tension by turning the drive belt
tensioner arm clockwise, and remove the drive belt.
SST 0924963010
SST
F13071
3.
DISCONNECT SUCTION HOSE
Remove the clip and disconnect the suction hose.
NOTICE:
Take care not to spill fluid on the drive belt.
4.
REMOVE PRESSURE FEED TUBE
Remove the union bolt, gasket and pressure feed tube.
5.
REMOVE PS VANE PUMP ASSEMBLY
Loosen the 2 bolts and PS vane pump assembly.
F13070
http://vnx.su
SR22
STEERING

SR0VS08
DISASSEMBLY
F11943
NOTICE:
1.
(a) Check that the pump rotates smoothly without abnormal
noise.
(b) Using a torque wrench, check the pump rotating torque.
Rotating torque:
2.
REMOVE SUCTION PORT UNION
(a) Remove the bolt and suction port union.
(b) Remove the Oring from the suction port union.
3.
REMOVE PRESSURE PORT UNION, FLOW CONTROL
VALVE AND SPRING
(a) Remove the pressure port union, flow control valve and
spring.
(b) Remove the Oring from the pressure port union.
4.
REMOVE OIL PRESSURE SWITCH
NOTICE:
Be careful not to drop the oil pressure switch.
If the oil pressure switch is dropped or strongly damaged, replace it with a new one.
5.
REMOVE REAR HOUSING
(a) Remove the 4 bolts and rear housing.
(b) Remove the Oring from the rear housing.
6.
REMOVE CAM RING, 10 VANE PLATES, VANE PUMP
ROTOR AND SIDE PLATE
(a) Remove the cam ring and 10 vane plates.
NOTICE:
Take care not to drop the vane plate.
(b) Using a screwdriver, remove the snap ring, vane pump rotor and side plate.
(c) Remove the 2 Orings from the side plate.
7.
REMOVE VANE PUMP SHAFT WITH VANE PUMP
PULLEY
http://vnx.su
SR23
STEERING

SR0VT08
INSPECTION
1.
Bushing
Vane Pump Shaft
Front Housing
F09875
Thickness
MEASURE OIL CLEARANCE BETWEEN VANE PUMP

SHAFT AND BUSHING
Using a micrometer and a caliper gauge, measure the oil clearance.
Standard clearance:
0.021 0.043 mm (0.0008 0.0017 in.)
If it is more than the maximum, replace the front housing and
vane pump shaft.
2.
(a)
INSPECT VANE PUMP ROTOR AND VANE PLATES

Using a micrometer, measure the height, thickness and
length of the 10 vane plates.
Minimum height: 7.6 mm (0.299 in.)
Minimum thickness: 1.405 mm (0.0553 in.)
Minimum length: 11.993 mm (0.4722 in.)
(b)

the vane pump rotor groove and vane plate.
Height
Length
N00372
Feeler Gauge
R10282
http://vnx.su
SR24
STEERING
If it is more than the maximum, replace the vane plate and/or

vane pump rotor with the one having the same mark stamped
on the cam ring.
Inscribed mark: 0, 1, 2, 3, or 4
HINT:
There are 5 vane plate lengths corresponding to the following
vane pump rotor and cam ring marks:
Inscribed Mark
F08475
Vane pump rotor and

cam ring mark
Vane plate part

number
Vane plate length

mm (in.)
44345 02110
12.001 12.003
(0.47248 0.47256)
44345 02120
11.999 12.001
(0.47240 0.47248)
44345 02130
11.997 11.999
(0.47232 0.47240)
44345 02140
11.995 11.997
(0.47224 0.47232)
44345 02150
11.993 11.995
(0.47216 0.47224)
3.
(a)
INSPECT FLOW CONTROL VALVE

Coat the flow control valve with power steering fluid and
check that it falls smoothly into the valve hole of the front
housing by its own weight.
(b)
Check the flow control valve for leakage. Close one of the
holes and apply compressed air of 392 490 kPa (4 5
kgf/cm2, 57 71 psi) into the opposite side hole, and confirm that air does not come out from the end hole.
F08476
Compressed Air
F08804
If necessary, replace the flow control valve with the one having
the same letter as inscribed on the front housing.
Inscribed mark: A, B, C, D, E or F
Inscribed Mark
Inscribed Mark
F08478
http://vnx.su
SR25
STEERING
4.
INSPECT SPRING
Using vernier calipers, measure the free length of the spring.
Minimum free length: 35.8 mm (1.409 in.)
If it is not within the specification, replace the spring.
Vernier Calipers
R08702
http://vnx.su
SR26
STEERING

SR0VU08
REPLACEMENT
NOTICE:
IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver with vinyl tape wound around its tip,
remove the oil seal.
NOTICE:
Be careful not to damage the bushing of the front housing.
Vinyl Tape
F08479
(b)
(c)
Coat a new oil seal lip with power steering fluid.

Using SST, press in the oil seal.
SST 0995060010 (0995100280),
0995070010 (0995107100)
NOTICE:
Make sure that the oil seal is installed facing in the correct
direction.
SST
Oil Seal
F08480
http://vnx.su
SR27
STEERING

SR0VV08
REASSEMBLY
NOTICE:
1.
COAT PARTS INDICATED BY ARROWS WITH POWER
STEERING FLUID (See page SR19)
2.
INSTALL VANE PUMP SHAFT WITH VANE PUMP
PULLEY
3.
(a)
INSTALL SIDE PLATE

Coat 2 new Orings with power steering fluid, and install
them to the side plate.
(b) Align the dent of the side plate with the dent of the front
housing, and install the side plate.
NOTICE:
Make sure that the side plate is installed facing in the correct direction.
F08482
4.
INSTALL CAM RING
Align the dent of the cam ring with the dent of the side plate, and
install the cam ring with the inscribed mark facing outward.
Inscribed Mark
F08483
5.
(a)
Inscribed Mark
Round End
INSTALL VANE PUMP ROTOR

Install the vane pump rotor with the inscribed mark facing
outward.
(b) Install a new snap ring to the vane pump shaft.
6.
INSTALL 10 VANE PLATES
Install the 10 vane plates with the round end facing outward.
F08484
7.
(a)
(b)
8.
INSTALL REAR HOUSING

it to the rear housing.
Align the straight pin of the rear housing with the dents of
the cam ring, side plate and front housing, and install the
rear housing with the 4 bolts.
INSTALL OIL PRESSURE SWITCH
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SR28
STEERING
9.
(a)
(b)
(c)
(d)
10.
(a)
(b)
11.
INSTALL SPRING, FLOW CONTROL VALVE AND

PRESSURE PORT UNION
Install the spring.
Install the flow control valve facing in the correct direction
(See page SR19).
it to the pressure port union.
Install the pressure port union.
INSTALL SUCTION PORT UNION
it to the suction port union.
Install the suction port union with the bolt.
(See page SR22)
http://vnx.su
SR29
STEERING

SR1C901
INSTALLATION
1.
(a)
(b)
(c)
INSTALL PS VANE PUMP ASSEMBLY

Insert the 2 bolts to the PS vane pump assembly.
Install the PS vane pump assembly.
Tighten the 2 bolts.
F13070
2.
INSTALL PRESSURE FEED TUBE
Install the pressure feed tube and gasket to the PS vane pump
assembly with union bolt.
Torque: 52 Nm ( 530 kgfcm, 38 ftlbf)
3.
CONNECT SUCTION HOSE
Connect the suction hose with the clip.
4.
INSTALL DRIVE BELT
Using SST, loosen the drive belt tension by turning the drive belt
tensioner arm clockwise, and install the drive belt.
SST 0924963010
SST
F13071
5.
INSTALL ENGINE UNDER COVER RH
Install the engine under cover RH with 5 bolts.
6.
BLEED POWER STEERING SYSTEM
(See page SR2)
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BODY ELECTRICAL
COMBINATION METER . . . . . . . . . . . . . . . . . .
POWER DOOR LOCK
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . .
DOUBLE LOCKING SYSTEM . . . . . . . . . . . . .
BE1
BE4
BE11
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
BE16

Manual Name
Pub. No.
RM599E

RM698E
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BE1
BODY ELECTRICAL
COMBINATION METER
COMBINATION METER
BE02803
CIRCUIT
Connector A
Connector B
I04817
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BE2
BODY ELECTRICAL
A5
A15
A3
COMBINATION METER
SPEEDOMETER
S
A18
TACHOMETER
WATER TEMP.
FUEL
A6
A12
A11
A19
OIL LEVEL
LCD
DISPLAY
ODO / TRIP
METER
A10
A9
B11
B24
OUTSIDE TEMP.
CLOCK
LCD
DISPLAY
B7
RHEOSTAT
B20
B25
Brake Warning
VOLTAGE
STABILIZER
B5
A22
B4
A21
Fuel filter Warning

Discharge Waring
Glow Plug Indicator
ABS Warning
B10
B16
B14
B8
A22
A25
A23
A20
A14
A1
B15
B18
B19
B17
B22
B9
Low Oil Pressure Warning

Check Engine Warning
O / D OFF Indicator
ECT SNOW Indicator
SLIP Indicator
VSC Warning
VSC OFF Indicator
ECT PWR Indicator
Rear Fog Light Indicator
High Beam Indicator
Right Turn Indicator
Left Turn Indicator
Open Door Warning
SRS Warning
Front Fog light Indicator
B26
A24
A26
B2
A17
B1
B13
B6
B3
I18195
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BE3
BODY ELECTRICAL
No.
1
3
5
6
9
10
11
12
14
15
17
18
19
20
21
22
23
24
25
26
1
2
3
4
5
6
7
.8
9
10
11
13
14
15
16
17
18
19
20
22
24
25
26
COMBINATION METER
Wire Harness Side

Ground (Power)
Engine ECU (M/T) or
Engine and ECT ECU (A/T)
Vehicle Speed Sensor
Engine ECU (M/T)
Ground
Outside Temperature Sender Gauge
Ground (Fuel)
Fuel Sender Gauge
Ground (Power)
Ground (Speed)
Turn Signal Switch (Right)
Other Parts
Oil Level Warning Switch
ABS & BA & TRC & VSC ECU (w/ ABS & BA & TRC & VSC)
Engine ECU (1CDFTV Glow)
Engine and ECT ECU (Gasoline Engine) or
Fuel Filter Warning Switch (Diesel Engine)
ECT Pattern Select Switch
Rear Fog Light Switch
Turn Signal Switch (Left)
HLP Fuse
Front Fog Light Switch
Alternator L Terminal
ABS, VSC System (w/ ABS) or
Ground (w/o ABS)
ECU+B Fuse
Taillight Relay
O/D Main Switch (A/T)
GAUGE Fuse
ABS ECU
Ground (Signal)
DOOR Fuse
EFI ECU (Gasoline Engine)
EGR ECU (Diesel Engine)
Headlight Dimmer Switch
Low Oil Pressure Warning Switch
IGN Fuse
Door Courtesy Switch
Airbag ECU
Taillight Relay
GAUGE Fuse
Ground (Signal)
Brake Fluid Level Warning Switch,
Brake Vacuum Warning Switch (1CDFTV) or
Parking Brake Switch (w/o ABS)
DOOR Fuse
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BE4
BODY ELECTRICAL
POWER DOOR LOCK CONTROL SYSTEM

BE1XO01
LOCATION
Ignition Switch
Instrument Panel Junction Block

D PWR Fuse
D Integration Relay
4 Door Control:
Power Window Master Switch
D Door Lock Manual Switch
Sedan models:
LH Door Lock Assembly

D Double Locking Motor
D Double Locking Switch
2 Door Control:
RH Door Lock Assembly

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I19378
BE5
BODY ELECTRICAL
Hatchback models:
Wagon models:


I18194
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BE6
BODY ELECTRICAL

BE1XP01
INSPECTION
1.
w/ Double locking system:

INSPECT DOOR KEY LOCK SWITCH CONTINUITY
UNLOCK
LOCK
Switch position
Tester connection
LOCK
5 10
OFF
Specified condition
Continuity
No continuity
If continuity is not as specified, replace the switch.

I19362
2.

INSPECT DOOR UNLOCK DETECTION SWITCH CONTINUITY
UNLOCK
LOCK
I19362
Switch position
Tester connection
OFF (Door Lock set to

LOCK)
ON (Door Lock set to

UNLOCK)
61
Specified condition
No continuity
Continuity
If continuity is not as specified, replace the switch.

3.

INSPECT DRIVERS DOOR LOCK MOTOR OPERATION
(a) Connect the positive (+) lead from the battery to terminal
3 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 position.
If operation is not as specified, replace the door lock assembly.
UNLOCK
LOCK
UNLOCK
LOCK
I19363
4.
2
UNLOCK
(a)
(b)
I19364

INSPECT DRIVERS DOOR PTC THERMISTOR OPERATION
Connect the negative () lead from the battery to terminal
2.
Connect the negative () lead from the ammeter to terminal 3 and the positive (+) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds.
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BE7
BODY ELECTRICAL
(c)
(d)
Disconnect the leads from terminals.

Approximately 60 seconds later, connect the positive (+)
lead from the battery to terminal 2 and the negative ()
lead to terminal 3, and check that the door lock moves to
the LOCK position.
LOCK
I19365
5.
3
UNLOCK
(a)
(b)
I19366

INSPECT DRIVERS DOOR PTC THERMISTOR OPERATION
Connect the positive (+) lead from the battery to terminal
3 and the negative () lead to terminal 2.
Attach a currentmeasuring probe to either the positive
(+) lead or the negative () lead, and check that the current changes from approximately 3.2 A to less than 0.5 A
within 20 to 70 seconds.
(c)
(d)

Approximately 60 seconds later, reverse the polarity, and
check that the door lock moves to the LOCK position.
LOCK
I19365
6.

INSPECT PASSENGERS DOOR LOCK MOTOR OPERATION
UNLOCK
LOCK
UNLOCK
LOCK
I19367
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BE8
BODY ELECTRICAL
7.
1
UNLOCK
(a)
(b)
I19368

INSPECT PASSENGERS DOOR PTC THERMISTOR
OPERATION
1.
(c)
(d)

the LOCK position.
LOCK
I19369
8.
1
UNLOCK
(a)
(b)
I19370

INSPECT PASSENGERS DOOR PTC THERMISTOR
OPERATION
(c)
(d)

LOCK
I19369
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BE9
BODY ELECTRICAL
9.

INSPECT REAR DOOR LOCK MOTOR OPERATION
LOCK
UNLOCK
UNLOCK
2
LOCK
I19371
10.
1
(a)
(b)
UNLOCK
I19372

INSPECT REAR DOOR PTC THERMISTOR OPERATION
1.
(c)
(d)

the LOCK position.
LOCK
I19373
11.
(a)
(b)
UNLOCK
I19374

INSPECT REAR DOOR PTC THERMISTOR OPERATION
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BE10
BODY ELECTRICAL
(c)
(d)

LOCK
I19373
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BE11
BODY ELECTRICAL
DOUBLE LOCKING SYSTEM

BE1XQ01
LOCATION
Ignition Switch

D PWR Fuse
D Integration Relay
4 Door Control:
Sedan models:

2 Door Control:

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I19378
BE12
BODY ELECTRICAL
Hatchback models:
Wagon models:


I18194
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BE13
BODY ELECTRICAL

BE1XR01
INSPECTION
1.
INSPECT DOUBLE LOCKING SYSTEM FUNCTION
HINT:
S
In case of doing the following inspection, must open one of the windows of the doors.
S
To set the double lock, turn the ignition switch OFF, pull out the key, open the drivers door and then
perform the lock operation on the wireless transmitter. Locking again within 5 sec, after the first locking
sets the double lock.
(a) Check that the double lock is set.
(1) With the glass window opened, set the double lock from the outside of a vehicle using a wireless
transmitter.
(2) Check that the doors wont open from the inside of the vehicle even operating the door lock knob
and inside door handle
(b) Check that the double lock is released (Case 1).
(1) Press the UNLOCK button on the wireless transmitter.
(2) Check that the doors will open from the inside of the vehicle by operating the door knob and inside
door handle.
(c) Check that the double lock is released (Case 2).
(1) With the glass window opened, set the double lock from the outside of a vehicle using a wireless
transmitter.
(2) Under this condition, insert the key into the ignition key cylinder, turn the ignition switch to ON
and check that the doors will open.
If you find any abnormal symptom in the check items of (a),(b) and (c), troubleshoot according to the Problem
Symptom Table.
2.
I19379
INSPECT DRIVERS DOUBLE LOCKING SWITCH

CONTINUITY
Switch position
Tester connection
OFF (Double Locking is

released)
ON (Double Locking is
set)
91
Specified condition
No continuity
Continuity
If continuity is not as specified, replace the door lock assembly.

3.
INSPECT DRIVERS DOUBLE LOCKING MOTOR OPERATION
(a) Set the Door Lock to LOCK position by the locking cable.
(b) Connect the positive (+) lead from the battery to terminal
7 and negative () lead to terminal 8, and check that the
Door Lock will not unlock by pulling the locking cable.
(c) Reverse the polarity and check that the Door Lock will unlock by pulling the locking cable.
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BE14
BODY ELECTRICAL
4.
I19375
INSPECT PASSENGERS AND REAR DOUBLE LOCKING SWITCH CONTINUITY

Switch position
Tester connection
OFF (Double Locking is

released)
ON (Double Locking is
set)
36
Specified condition
No continuity
Continuity
If continuity is not as specified, replace the door lock assembly.

5.
INSPECT PASSENGERS AND REAR DOUBLE LOCKING MOTOR OPERATION
(a) Set the Door Lock to LOCK position by the locking cable.
(b) Connect the positive (+) lead from the battery to terminal
4 and negative () lead to terminal 5, and check that the
Door Lock will not unlock by pulling the locking cable.
(c) Reverse the polarity and check that the Door Lock will unlock by pulling the locking cable.
6.
Wire Harness Side
INSPECT DOUBLE LOCKING DOOR CONTROL

RELAY CIRCUIT
Disconnect connector from the double locking door control relay and inspect the connectors on the wire harness
side as follows.
(a)
I12350
Tester connection
14 Ground
Condition
Specified condition
Constant
Battery voltage
Turn ignition switch ON
Battery voltage
Turn ignition switch OFF
No voltage
Constant
Continuity
15 Ground
25 Ground
If circuit is as specified, replace the double locking door control

relay.
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BE15
BODY ELECTRICAL
From back side:

9
11 10
25
19
(b)
18
Tester connection
Connect the wire harness side connector to the double

locking door control relay and inspect the connector from
the back side as shown in the chart.
17
16
I15105
Condition
Specified condition
Drivers door lock control switch LOCK
Below 2.0 V
Drivers door lock control switch UNLOCK
More than 5.7 V
Drivers door lock switch LOCK
More than 5.7 V
Drivers door lock control switch UNLOCK
Below 2.0 V
Di
Driver
door
d
key
k lock
l k and
d unlock
l k switch
it h LOCK
B l 2.0
Below
20V
Drivers door is unlocked
Below 1.0 V
Drivers door is locked
More than 5.0 V
Driver door is opened
Below 1.0 V
Driver door is closed
More than 5.0 V
Passenger door is opened
Below 1.0 V
Passenger door is closed
More than 5.0 V
7 25
8 25
9 25
11 25
18 25
19 25
If circuit is not as specified, wiring diagram and inspect the circuits connected to other parts.
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BE16
BODY ELECTRICAL
AUDIO SYSTEM
AUDIO SYSTEM
BE1XS01
DESCRIPTION
1.
RADIO WAVE BAND
The radio wave bands used in radio broadcasting are as follows:
Frequency
30 kHz
Designation
300 kHz
LF
LW
Radio wave
Modulation
3 MHz
MF
AM (MW)
Amplitube modulation
30 MHz
HF
SW
300 MHz
VHF
FM (UKW)
Frequency modulation
LF: Low Frequency

MF: Medium Frequency
HF: High Frequency
VHF: Very High Frequency
2.
SERVICE AREA
There are great differences in the size of the service area for AM
and FM monaural. Sometimes FM stereo 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 (noise)
easily.
FM (Stereo)
FM (Monaural)
AM
BE2818
3.
RECEPTION PROBLEMS
Besides the problem of static, there are also the problems
called fading, multipath and fade out. These problems are
caused not by electrical noise but by the nature of the radio
waves themselves.
Fading
(1)
lonosphere
Fading
Besides electrical interference, AM broadcasts are
also susceptible to other types of interference, especially at night. This is because AM radio waves
bounce off the ionosphere at night. These radio
waves then interfere with the signals from the same
transmitter that reach the vehicles antenna directly.
This type of interference is called fading.
BE2819
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BE17
BODY ELECTRICAL
(2)
Multipath
AUDIO SYSTEM
Multipath
One type of interference caused by the bounce of
radio waves off of obstructions is called multipath.
Multipath occurs when a signal from the broadcast
transmitter antenna bounces off buildings and
mountains and interferes with the signal that is received directly.
BE2820
(3)
Fade Out
BE2821
Fade Out
Because FM radio waves are of higher frequencies
than AM radio waves, they bounce off buildings,
mountains, and other obstructions. For this reason,
FM signals often seem to gradually disappear or
fade away as the vehicle goes behind a building or
other obstruction. This is called fade out.
4.
COMPACT DISC PLAYER
Compact Disc (hereafter called CD) Players use a laser beam
pickup to read the digital signals recorded on the CD and reproduce analog signals of the music, etc. There are 4.7 in. (12
cm) and 3.2 in. (8 cm) discs in the CD player.
HINT:
Never attempt to disassemble or oil any part of the player unit.
Do not insert any object other than a disc into the magazine.
NOTICE:
CD players use an invisible laser beam which could cause
hazardous radiation exposure. Be sure to operate the player correctly as instructed.
5.
Example :
Head
Capstan
(a)
(b)
Pinch Roller
Tape Player/Head Cleaning:

MAINTENANCE
Raise the cassette door with your finger.
Next, using a pencil or similar object, push in the guide.
Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans.
N17398
6.
CD Player/Disc Cleaning:
MAINTENANCE
If the disc gets dirty, clean the disc by wiping the surface from
the center to outside in the radial directions with a soft cloth.
NOTICE:
Do not use a conventional record cleaner or antistatic preservative.
BE4331
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BE18
BODY ELECTRICAL
7.
(a)
AUDIO SYSTEM
OUTLINE OF AVCLAN
What is AVCLAN?
AVCLAN is the abbreviation, which stands for Audio Visual CommunicationLocal Area Network.
This is a unified standard codeveloped by 6 audio manufactures associated with Toyota Motor Corporation.
The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication
and communication signal.
Radio Receiver Assembly
Multi Display
I12412
(b)
Objectives
Recently the car audio system has been rapidly developed and functions have been changed drastically. The conventional system has been switched to the multimedia type such as a navigation system. At the same time the level of customers needs to audio system has been upgraded. This lies behind this standardization.
The concrete objectives are explained below.
(1) When products by different manufactures were combined together, there used to be a case that
malfunction occurred such as sound did not come out. This problem has been resolved by standardization of signals.
(2) Various types of after market products have been able to add or replace freely.
(3) Because of the above (2), each manufacture has become able to concentrate on developing
products in their strongest field. This has enabled many types of products provided inexpensively.
(4) Conventionally, a new product developed by a manufacture could not be used due to a lack of
compatibility with other manufactures products. Because of this new standard, users can enjoy
compatible products provided for them timely.
The above descriptions are the objectives to introduce AVCLAN. By this standardization, development of
new products will no longer cause systematic errors. Thus, this is very effective standard for a product in the
future.
HINT:
S
When +B short or GND short is detected in AVCLAN circuit, communication stops. Accordingly the
audio system does not function normally.
S
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, navigation ECU is the master unit.)
S
The car audio system using AVCLAN circuit has a diagnosis function.
S
Each product has its own specified numbers called physical address. Numbers are also allotted to
each function in one product, which are called logical address.
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BE19
BODY ELECTRICAL
AUDIO SYSTEM
BE1XT01
TROUBLESHOOTING
1.
DISPLAYING RESULTS
Results for each check are displayed as follows:
S
GOOD:
No DTC is detected for both System Check Confirmation and Diagnosis Memory Response.
S
NCON:
The Component does not respond to the Diagnosis On Instruction command.
Applicable to only the system where connected components are limited to be used.
S
ECHN:
Application of new version has been confirmed by the Diagnosis On Check, and there is one
or more DTC which indicates Replacement in the System Check Result Response or Diagnosis Memory Response.
S
CHEC:
Application of new version has been confirmed by the Diagnosis On Check, and there is no DTC
which indicates Replacement in the System Check Result Response or Diagnosis Memory
Response, but one or more DTC which indicated Check is identified.
S
OLD:
Application of old version is confirmed by the Diagnosis On Check, and DTC is identified in the
System Check Result Response or Diagnosis Memory Response.
S
NRES:
No response is identified to the System Check Start Instruction and Request for System Check
Result commands.
Example:
TUNE DOWN
TUNE UP
1 Switch
2 Switch
3 Switch
TAPESCD
5 Switch
6 Switch
I18196
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BE20
BODY ELECTRICAL
AUDIO SYSTEM
2.
FUNCTION
HINT:
S
Check the present and past condition of components by performing the System Check and collecting
stored DTC memories.
S
Check results shall be displayed as one of six following indications: GOOD, ECHN, CHEC
,NCON, OLD or NRES.
(a) Display Screen for Service Check.
Example:
Connection parts ( physical address): Multi Display (P160), Radio Receiver (P190), CD changer (P360)
Turn ignition switch ON.
Push the TAPESCD switch 3
times while pressing ch1 and
ch6 switches.
Normal Mode
L 3 beeps
Service Check Mode
HINT:
To exit from diagnosis mode,
press the TAPESCD switch for
1.7 sec. or turn ignition switch to
ACC or OFF
Physical Address
(When checking, P160 is blinking.)
P160
TUNE UP
TUNE DOWN
ch2
Result (Replacing)
ECHN
ch3
TUNE UP
TUNE DOWN
Physical Address
P190
TUNE DOWN
TUNE UP
ch2
Result (Check)
CHEC
ch3
P360
TUNE DOWN
Physical Address
TUNE UP
ch2
OLD
ch3
OLD Detail
Display Mode
(Refer to (d))
ch5 (1.7 sec.) L A long beep (3 sec.)
: Indicates a switch operation

After 3 sec.
Memory Clear Mode
CHEC Detail
Display Mode
(Refer to (c))
TUNE UP
TUNE DOWN
Result (Old)
ECHN Detail
Display Mode
(Refer to (b))
CLr
S After the memory is cleared, only the physical address is displayed cyclically.
S When rechecking (ch1 switch is pressed) in that condition, the result is also
displayed as shown above.
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BE21
BODY ELECTRICAL
(b)
AUDIO SYSTEM
ECHN Detail Display Mode Screen

P160
TUNE UP
TUNE DOWN
Service Check Mode

TUNE UP
CLr
ECHN
TUNE DOWN
ch2
ch3
ch5 (Along)
ECHN Detail Display Mode

P160
Physical Address of Component

TUNE UP
TUNE DOWN
SyS
TUNE UP
TUNE DOWN
1***
Logical Address
Details for 1st

Component
TUNE UP
TUNE DOWN
122
DTC (Refer to diagnostic

trouble code chart)
TUNE UP
TUNE DOWN
COdE
TUNE UP
TUNE DOWN
2***
Logical Address
TUNE UP
TUNE DOWN
2E4
TUNE DOWN

trouble code chart)
TUNE UP
2***
TUNE DOWN
Auxiliary Code
TUNE UP
2**
TUNE DOWN
Connection Check Code

TUNE UP
2**
TUNE DOWN
Number of Occurrence
TUNE UP
Continued if more than one DTC is identified.

TUNE DOWN
TUNE UP
Detail code is displayed cyclically.
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Details for 2nd

Component
BE22
BODY ELECTRICAL
(c)
AUDIO SYSTEM
CHEC Detail Display Mode Screen

P190
TUNE UP
TUNE DOWN
Service Check Mode

TUNE UP
CHEC
CLr
TUNE DOWN
ch3
ch2
CHEC Detail Display Mode
P190
ch5 (Along)

TUNE UP
TUNE DOWN
COde
TUNE UP
TUNE DOWN
1**
TUNE DOWN
1E4
TUNE DOWN
1P160
1**
TUNE UP
Auxiliary Code (*1)
Details for 1st

Component

TUNE UP
TUNE DOWN
1**
Number of Occurrence (*1)

TUNE UP
TUNE DOWN
2**
Logical Address
TUNE UP
TUNE DOWN
2DC
TUNE DOWN
2**

trouble code chart)
TUNE UP
Auxiliary Code (*1)
TUNE UP
TUNE DOWN
2**

TUNE UP
TUNE DOWN
2**
(*1): There are some diagnostic

codes witch might not be displayed.
In this case, is displayed.
TUNE UP
trouble code chart)
TUNE UP
TUNE DOWN
Logical Address

TUNE DOWN
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TUNE UP
Details for 2nd

Component
BE23
BODY ELECTRICAL
(d)
AUDIO SYSTEM
OLD Detail Display Mode Screen

P360
TUNE UP
TUNE DOWN
Service Check Mode

TUNE UP
OLD
CLr
TUNE DOWN
ch3
ch2
CHEC Detail Display Mode
P360
ch5 (Along)

TUNE UP
TUNE DOWN
COde
TUNE UP
TUNE DOWN
1**
TUNE DOWN
1E4
TUNE DOWN
1P160
1**
TUNE UP
Auxiliary Code (*1)
Details for 1st

Component

TUNE UP
TUNE DOWN
1**

TUNE UP
TUNE DOWN
2**
Logical Address
TUNE UP
TUNE DOWN
2DC
TUNE DOWN
2**

trouble code chart)
TUNE UP
Auxiliary Code (*1)
Details for 2nd

Component
TUNE UP
TUNE DOWN
2**

TUNE UP
TUNE DOWN
2**
(*1): There are some diagnostic

codes witch might not be displayed.
In this case, is displayed.
TUNE UP
trouble code chart)
TUNE UP
TUNE DOWN
Logical Address

TUNE DOWN
TUNE UP
(e)
Recheck
(1) Pressing the [ch1] key in Service Check Mode executes recheck.
(2) To display the recheck process, follow the sequence indicated Display Screen for Service Check.
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BE24
BODY ELECTRICAL
3.
AUDIO SYSTEM
DIAGNOSIS TROUBLE CODE CHART

Meaning
Terms
Physical address Threedigit code (shown in hexadecimal) which is given to each component comprising the
AVC LAN
Corresponding to the function, individual symbols are specified..
Logical address
Twodigit code (shown in hexadecimal) which is given to each function comprising the inner system
of the AVC LAN.
Physical address: 160 Multi display

Logical address
DTC Diagnosis item
Diagnosis content
Countermeasure and
inspected parts
01
(Communication
control)
21
ROM Error
Abnormal condition of ROM is detected.
Replace multidisplay assembly.
01
(Communication
control)
22
RAM Error
Abnormal condition of RAM is detected.
Replace multidisplay assembly.
01 *2
(Communication
Control)
D8
No response to Component shown by auxiliary D Check harness for power supply

code is or was disconnected from of component shown by auxiliary
connection
code
system after engine is started.
check
D Check harness for communication system of component shown
by auxiliary code
01 *1
(Communication
Control)
D9
Last Mode
Error
Component operated (sound and/

or image was provided) before engine stop is or was disconnected
with ignition switch in ACC or ON.
D Check harness for power supply

of component shown by auxiliary
code
D Check harness for communication system of component shown
by auxiliary code
01
(Communication
Control)
DA
No Response
to ON/OFF
Instruction
No response is identified when

changing mode (audio and visual
mode change). Detected when
sound and picture does not change
by button operation.

of component shown by auxiliary
code.
D Check harness for communication system of component shown by
auxiliary code.
D If error occurs again, replace
component shown by auxiliary
code.
01 *1
(Communication
Control)
DB
Mode Status
Error
Dual sound is detected.

system of component shown by
auxiliary code.
auxiliary code.
01 *3
(Communication
Control)
DC
Transmission
Error
Transmission to component shown

by auxiliary code has been failed.
(This code does not necessarily
mean actual failure.)
If same component shown by auxiliary code is recorded in other component(s), check harness for power
supply and communication system
of components shown sub code.
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BE25
BODY ELECTRICAL
AUDIO SYSTEM
After engine start, slave component D Check harness for power supply
has been disconnected and con- system of component shown by
nected again.
auxiliary code.
auxiliary code.
01 *4
(Communication
Control)
DE
Slave Reset
(Momentary
Interruption)
01
(Communication
Control)
E4
Multiple Frame Multiple frame transmission is Since this DTC is provided for engineering, it may be detected when
Abort
aborted.
no actual failure exists.
*1: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.
*2: It is stored when 240 sec. has passed after the power supply connector is pulled out after engine start.
*3: It may be stored when the engine key is turned again 1 min. after engine start.
*4: It may be stored when the engine key is turned again after engine start.
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BE26
BODY ELECTRICAL
AUDIO SYSTEM
Physical address: 190 Radio receiver assembly

Logical address
DTC Diagnosis item
Diagnosis content
Countermeasure and
inspected parts
01
(Communication
Control)
21
ROM Error
Error is detected in internal ROM.
Replace radio receiver assembly.
01
(Communication
Control)
22
RAM Error
Error is detected in internal RAM.
01 *1
(Communication
Control)
D6
Absence of
Master
Component in which this code is recorded has been disconnected from

system with ignition in ACC or ON.
Or, when this code was recorded,
multidisplay assembly was disconnected.
01 *4
(Communication
Control)
D7
Connection
Check Error
Component in which this code is recorded has been disconnected

from system after engine start.
Or, when this code was recorded,
multidisplay assembly was disconnected.

system of multi display.
D Check harness for communication system of multi display.
01 *2
(Communication
Control)
DC
Transmission
Error
Transmission to component shown

by auxiliary code has been failed.
(Detecting this DTC does not necessary mean actual failure.)
D If same auxiliary code is recorded

in other component, check harness
for power supply and communication system of components shown
sub code.
01 *3
(Communication
Control)
DD
Master Reset
(Momentary
Interruption)
After engine is started, multidis- D If this error occurs frequently, replay assembly was disconnected place multidisplay assembly.
and connected again from system.
01
(Communication
Control)
E0
Registration
Completion
Instruction
Error
Registration Completion Instruc- D Since this DTC is provided for ention command from multi display gineering purpose, it may be decannot be received.
tected when no actual failure exists.
01 *1
(Communication
Control)
E1
Audio
processor ON
error
While source equipment is operat- D Check harness for power supply

of multidisplay assembly.
ing, AMP output is stopped.
D Check harness for communication system of multidisplay assembly.
01
(Communication
Control)
E2
ON/OFF
Instruction
Parameter
Error
Error occurs in ON/OFF controlling D Replace multidisplay assembly.

command from multidisplay assembly.
01
(Communication
Control)
E3
Registration
Request
Transmission
Registration Request command is D Since this DTC is provided for enoutput from slave component.
gineering purpose, it may be detected when no actual failure exists.
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system of multi display.
D Check harness for communication system of multi display.
system of radio receiver assembly.
D Check harness for communication system of radio receiver assembly.
BE27
BODY ELECTRICAL
AUDIO SYSTEM
01
(Communication
Control)
E4
Plural Frame
Abort
Plural frame transmission is D Since this DTC is provided for engineering purpose, it may be deaborted.
tected when no actual failure exists.
62
(CD player)
42
No Disc
Readout
Disc cannot be read.
Inspect CD.
62
(CD player)
44
CD Error
Error is detected in CD player.
62
(CD player)
51
EJECT Error
CD cannot be ejected.
62
(CD player)
46
Scratched/
Scratches or dirt is found on CD sur- Inspect CD.
Reversed Disc face or CD is set upside down.
*1: Even if no failure is detected, it may be stored depending on the battery condition or voltage for starting an engine.
*2: It may be stored when the engine key is turned again 1 min. after engine start.
*3: It may be stored when the engine key is turned again after engine start.
*4: When 210 sec. has passed after pulling out the power supply connector of the master component with the ignition
switch in ACC or ON, this code is stored.
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BE28
BODY ELECTRICAL
AUDIO SYSTEM
BE1XU01
LOCATION
Steering Switch
Multidisplay
Ignition Switch

D RAD & CIG Fuse
I18197
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BE29
BODY ELECTRICAL
AUDIO SYSTEM
BE1XV01
INSPECTION
INSPECT MULTIDISPLAY CIRCUIT
Disconnect the connectors from the multidisplay, and inspect
the connector on the wire harness side.
I12240
Tester connection
4 Ground
Condition
Specified condition
Constant
Continuity
Ignition switch ON
Battery voltage
Ignition switch LOCK
No voltage
Constant
Battery voltage
Ignition switch ACC or ON
No voltage
Ignition switch LOCK
Battery voltage
7 Ground
8 Ground
18 Ground
If the circuit is not as specified, inspect the circuits connected

to other parts.
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BODY
CLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRS AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . .
BO1
BO3
BO4
BO5

Manual Name
Pub. No.
RM599E

RM698E
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BO1
BODY
CLIP
CLIP
BO19D01
REPLACEMENT
The removal and installation methods of typical clips used in body parts are shown in the table below.
HINT:
If the clip is damaged during the operation, always replace it with a new clip.
Shape (Example)
Removal/Installation
Pliers
Clip Remover
Screwdriver
Scraper
V00005
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BO2
BODY
CLIP
Shape (Example)
Removal/Installation
Removal
Installation
Removal
Installation
V00012
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BO3
BODY
SRS AIRBAG
SRS AIRBAG
BO19E01
PRECAUTION
The TOYOTA AVENSIS/CORONA is equipped with an SRS (Supplemental Restraint System) such as the
driver airbag, front passenger 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 serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read
the precautionary notices in the RS section.
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BO4
BODY
FRONT BUMPER
FRONT BUMPER
BO18F02
COMPONENTS
Headlamp Washer Nozzle RH
Clamp
Headlamp Washer Hose
x5
Clamp
Radiator Support Seal

Turn Signal Light
Headlamp Washer Nozzle LH
Turn Signal Light
Radiator Grill
Support Bracket Upper
Bumper Bracket RH
Support Bracket
Reinforcement
20 (205, 15)
Front Bumper Pad
Fog Light RH
Clip
Front Bumper Cover
Radiator Grill Finish Plate RH
Clip
w/o Fog Light

Radiator Grill Lower LH
w/o Fog Light
Radiator Grill Lower RH
Bumper Bracket LH
x8
x8
Fog Light LH
Radiator Grill Finish Plate LH
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H15307
BO5
BODY
INSTRUMENT PANEL
INSTRUMENT PANEL
BO19J03
COMPONENTS
w/ Curtain shield air bag:
Front Pillar Garnish
Curtain Shield Airbag

G
Reinforcement
C
G C C
G
w/ Curtain shield
air bag:
G
No. 1 Brace
A
A
Instrument Panel
H
H
H
E
Front Door Opening Trim
D
18 (185, 13)
Rear Door Opening Trim

D
No. 1 Register
Cowl Side Trim
Combination Meter
Cluster Finish Panel
Front Door Scuff Plate

E E
Lower Finish Panel
Center Pillar Lower Garnish

E
E
Column Cover
Rear Door Scuff Plate
Center Cluster
Finish Panel
Glove Compartment Door
50 (510, 37)
x3
No. 1 Under Cover

M/T:
Shift Knob
F
Combination Switch
F
F
Steering Wheel
Rear Console Box
Steering Wheel Pad

B B
E
Parking Brake Hole Cover
Box Bottom Mat

No. 2 Box Bottom Mat
Cowl Side Trim
Box Bottom Panel

Rear Door Opening Trim
Center Pillar Lower Garnish
H15309
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BO6
BODY
Defroster Nozzle
No. 1 Side Defroster Duct
INSTRUMENT PANEL
No. 2 Side Defroster Duct

E
No. 3 Heater to Register Duct

No. 4 Heater to Register Duct
E
E
E
No. 1 Pin
E
No. 1 Pin
E
No.1 Heater to
Register Duct
E
Front Passenger
Airbag Assembly
E
E
No. 2 Side Defroster
Nozzle
No. 2 Register
E
E
E
RadioTuner Mounting Bracket
Center Bracket
E
E
E
E
Wire Harness
H15308
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BO7
BODY
INSTRUMENT PANEL
HINT:
Screw shapes and size are indicated in the table below. The codes (A H) correspond to those indicated
on the previous page.
mm (in.)
Shape
Size
Shape
Size
Shape
Size
=8
(0.31)
=6
(0.24)
=6
(0.24)
L = 16
(0.63)
L = 20
(0.79)
L = 18
(0.71)
=6
(0.24)
= 5.22
(0.2055)
=5
(0.20)
L = 16
(0.63)
L = 16
(0.63)
L = 18.5
(0.728)
=8
(0.31)
=6
(0.24)
H03703
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BO8
BODY
INSTRUMENT PANEL
BO3VQ01
REMOVAL
1.
2.
REMOVE FRONT DOOR OPENING TRIMS

REMOVE FRONT PILLAR GARNISHES
(a)
I12491
w/ Curtain Shield Airbag:

(1) Remove the 2 bolts.
(2) Pack the airbag with protection cover.
(3) Using a screwdriver, raise the pillar garnish cover.
(4) Remove the bolt, pillar garnish cover and front pillar
garnish.
NOTICE:
Protection rang is from instrument panel to ceiling.
(b) Remove the front door scuff plates.
(c) Remove the cowl side trims.
(d) Remove the rear door opening trims.
(e) Remove the rear door scuff plates.
(f)
Remove the center pillar lower covers.
(g) Remove the front seats.
3.
REMOVE STEERING WHEEL (See page SR6)
4.
(a)
(b)
5.
6.
7.
REMOVE LOWER FINISH PANEL

Remove the 2 screws and hood lock control lever.
Remove the 2 screws and lower finish panel.
REMOVE COLUMN COVER (See page SR6)
REMOVE COMBINATION SWITCH (See page
SR6)
REMOVE STEERING COLUMN (See page SR6)
H03659
8.
(a)
(b)
: 4 Clips
REMOVE CLUSTER FINISH PANEL

Remove the 2 screws.
Using a screwdriver, remove the cluster finish panel, then
disconnect the connector.
HINT:
Tape the screwdriver tip before use.
9.
REMOVE COMBINATION METER
H03660
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BO9
BODY
INSTRUMENT PANEL
10. REMOVE NO. 1 REGISTER

Using a screwdriver, remove the No. 1 register.
HINT:
: 4 Clips
H03661
11. REMOVE NO. 1 UNDER COVER

Using a screwdriver, remove the No. 1 under cover.
HINT:
: 3 Clips
H16639
12.
(a)
REMOVE GLOVE COMPARTMENT DOOR

Remove the damper clip from the bracket as shown in the
illustration.
(b)
13.
Remove the 2 glove shaft and glove compartment door.

REMOVE PARKING BRAKE HOLE COVER
14.
(a)
REMOVE REAR CONSOLE BOX

M/T:
Remove the shift lever knob.
Remove the box bottom mat, No. 2 box bottom mat and
box bottom panel.
Remove the 2 bolts, 4 caps, 4 screws and rear console
box.
H16437
H16640
(b)
(c)
H03664
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BO10
BODY
: 6 Clips
15.
(a)
INSTRUMENT PANEL
REMOVE CENTER CLUSTER FINISH PANEL

Using a screwdriver, remove the 6 clips of the center cluster finish panel.
HINT:
H15310
(b)
(c)
Remove the center cluster finish panel with holding up as

shown in the illustration.
16.
(a)
(b)
REMOVE INSTRUMENT PANEL

Remove the 2 bolts and front passenger airbag assembly.
Remove the 6 screws and 3 nuts.
17.
18.
REMOVE NO. 1 BRACE

REMOVE REINFORCEMENT
H16288
H03666
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BO11
BODY
INSTRUMENT PANEL
BO2J402
INSTALLATION
1.
2.
INSTALL REINFORCEMENT
INSTALL NO. 1 BRACE
3.
(a)
(b)
INSTALL INSTRUMENT PANEL

Install the 6 screws and 3 nuts.
Install the passenger airbag assembly with the 2 bolts.
H03666
: 6 Clips
4.
INSTALL CENTER CLUSTER FINISH PANEL
Install the panel, then connect the connectors.
H15310
5.
(a)
6.
INSTALL REAR CONSOLE BOX

Install the console box with the 2 bolts and 4 caps, 4
screws.
Install the box bottom panel, No. 2 box bottom mat and
box bottom mat.
M/T:
Install the shift lever knob.
INSTALL PARKING BRAKE HOLE COVER
7.
(a)
(b)
INSTALL GLOVE COMPARTMENT DOOR

Install the glove compartment door with the 2 glove shaft.
Install the damper clip.
(b)
(c)
H03664
H16640
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BO12
BODY
INSTRUMENT PANEL
8.
INSTALL NO. 1 UNDER COVER
Install the No. 1 under cover.
: 3 Clips
H16639
9.
INSTALL NO. 1 REGISTER
Install the No. 1 register.
10. INSTALL COMBINATION METER
: 3 Clips
H03661
11.
(a)
: 3 Clips
(b)
INSTALL CLUSTER FINISH PANEL

Install the cluster finish panel, then connect the connector.
Install the 2 screws.
12.
13.
14.
INSTALL STEERING COLUMN (See page SR6)

INSTALL COMBINATION SWITCH (See page SR6)
INSTALL COLUMN COVER (See page SR6)
15.
(a)
(b)
INSTALL LOWER FINISH PANEL

Install the lower finish panel with the 2 screws.
Install the hood lock control lever.
H03660
H03659
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BO13
BODY
16.
17.
18.
19.
20.
21.
22.
INSTRUMENT PANEL
INSTALL STEERING WHEEL (See page SR6)

INSTALL FRONT SEATS
INSTALL CENTER PILLAR LOWER COVERS
INSTALL REAR DOOR SCUFF PLATES
INSTALL REAR DOOR OPENING TRIMS
INSTALL COWL SIDE TRIMS
INSTALL FRONT DOOR SCUFF PLATES
(a)
I12491
w/ Curtain Shield Airbag:

(1) Remove the protection cover.
(2) Install the 2 bolts.
(3) Install the pillar garnish cover with the bolt.
NOTICE:
Be sure to tighten the bolt.
(4) Fell the pillar garnish cover.
(b) Install the front pillar garnishes.
(c) Install the front door opening trims.
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AIR CONDITIONING
AIR CONDITIONING SYSTEM . . . . . . . . . . . .
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . .
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . .
AC1
AC2
AC5
AC8
COMPRESSOR AND
MAGNETIC CLUTCH . . . . . . . . . . . . . . . . . . .
AIR INLET SERVOMOTOR . . . . . . . . . . . . . . .
AIR MIX SERVOMOTOR . . . . . . . . . . . . . . . . . .
AC11
AC15
AC19
AIR OUTLET SERVOMOTOR . . . . . . . . . . . . .

AIR CONDITIONER
CONTROL ASSEMBLY . . . . . . . . . . . . . . . . .
AC23
AIR CONDITIONER AMPLIFIER . . . . . . . . . . .
AC30
AC27

Manual Name
Pub. No.
RM599E

RM698E
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AC1
AIR CONDITIONING
AIR CONDITIONING SYSTEM
AIR CONDITIONING SYSTEM

AC39E01
INSPECT IDLEUP SPEED
(a) Warm up engine.
(b) Inspect idleup speed when the these conditions are established.
S
Warm up engine
S
Blower speed control switch at HI position
S
A/C switch ON
S
Temperature control dial at COOL position
1ZZFE, 3ZZFE engine models (M/T):
Magnetic clutch not engaged: 650 50 rpm
Magnetic clutch engaged: 800 50 rpm
1ZZFE, 3ZZFE engine models (A/T):
1AZFSE engine models (M/T):
1AZFSE engine models (A/T):
If idle speed is not as specified, check Idle control system.
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AC2
AIR CONDITIONING
DRIVE BELT
DRIVE BELT
AC2I602
INSPECT DRIVE BELTS INSTALLATION CONDITION
Check that the drive belt fits properly in the ribbed grooves.
Correct
Wrong
CH0086
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AC3
AIR CONDITIONING
DRIVE BELT
AC39F01
REMOVAL
1.

REMOVE DRIVE BELT
arm clockwise, and remove the drive belt.
B00145
2.
1AZFSE Engine:
REMOVE DRIVE BELT
Using the SST, loosen the drive belt tension by turning the drive
belt tensioner arm clockwise, and remove the drive belt.
SST 0924963010
F13071
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AC4
AIR CONDITIONING
DRIVE BELT
AC39G01
INSTALLATION
1.

INSTALL DRIVE BELT
Turning the drive belt tensioner arm clockwise, and install the
drive belt.
B00145
2.
1AZFSE Engine:
REMOVE DRIVE BELT
Using the SST, turning the drive belt tensioner arm clockwise,
and install the drive belt.
SST 0924963010
F13071
3.
CHECK DRIVE BELT INSTALLING CONDITION
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AC5
AIR CONDITIONING
MANIFOLD GAUGE SET
MANIFOLD GAUGE SET

AC2A703
SET ON
1ZZFE, 3ZZFE, 1AZFSE Engines
LHD:
RHD:
1.
A : Low Pressure Charging Hose

B : High Pressure Charging Hose
I18808
CONNECT CHARGE HOSE TO MANIFOLD GAUGE

SET
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 CAPS FROM SERVICE VALVE ON REFRIGERANT LINE
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AC6
AIR CONDITIONING
5.
MANIFOLD GAUGE SET
CONNECT QUICK DISCONNECT ADAPTER TO SERVICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, slide,
then slide the sleeve of the quick disconnect adapter downward
to lock it.
Sleeve
N04392
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AC7
AIR CONDITIONING
MANIFOLD GAUGE SET

AC2A802
SET OFF
1.
2.
N06553
CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE

SET
DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve.
3.
INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE
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AC8
AIR CONDITIONING
REFRIGERANT LINE
REFRIGERANT LINE
AC2IB01
1.
INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2.
INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
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AC9
AIR CONDITIONING
REFRIGERANT LINE
AC2IC02
LOCATION
1ZZFE, 3ZZFE, 1AZFSE Engines
LHD models:
Piping Clamp
Suction Hose
10 (100, 7)
5.5 (55, 48 in.lbf)
Liquid Tube
10 (100, 7)
Compressor
10 (100, 7)
Discharge Hose
Condenser
RHD models:
Liquid Tube
Piping Clamp
Suction Hose
10 (100, 7)
10 (100, 7)
Compressor
5.5 (55, 48 in.lbf)

10 (100, 7)
Condenser
Discharge Hose
Nm (kgfcm, ftlbf)
: Specified torque
I18809
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AC10
AIR CONDITIONING
REFRIGERANT LINE
AC2ID02
REPLACEMENT
1.
DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2.
REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
3.
TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE:
Connections should not be torqued tighter than the specified torqued.
Part tightened
Nm
kgfcm
ftlbf
Condenser x Discharge tube
5.5
55
48 in.lbf
Condenser x Liquid tube
5.5
55
48 in.lbf
Compressor x Discharge tube
10
100
Compressor x Suction tube
10
100
4.
EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT

Specified amount: 460 20 g (16.23 0.71 oz.)
5.
INSPECT FOR LEAKAGE OF REFRIGERANT
6.
INSPECT AIR CONDITIONING OPERATION
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AC11
AIR CONDITIONING
COMPRESSOR AND MAGNETIC CLUTCH
COMPRESSOR AND MAGNETIC

CLUTCH
AC1GA05
1.
INSPECT COMPRESSOR FOR METALLIC SOUND
Check there is abnormal metallic sound from the compressor
when the A/C switch is ON.
If abnormal metallic sound is heard, replace the compressor assembly.
2.
INSPECT REFRIGERANT PRESSURE (See page
AC1)
3.
INSPECT VISUALLY FOR LEAKAGE OF REFRIGERANT
If there is any leakage, replace the compressor assembly.
4.
2
1
I12997
INSPECT COMPRESSOR LOCK SENSOR RESISTANCE

(a) Disconnect the connector.
(b) Measure resistance between terminals 1 and 2 .
Standard resistance:
165 205 at 20 C (68 F)
If resistance is not as specified, replace the sensor.
5.
CHECK FOR LEAKAGE OF GREASE FROM CLUTCH
BEARING
6.
CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR
ROTOR
7.
INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start engine.
(b) Check for abnormal noise from the compressor when the
A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
8.
(a)
(b)
INSPECT MAGNETIC CLUTCH OPERATION

Disconnect the connector.
Connect the positive (+) lead form the battery to terminal
3 and the negative () lead to the body ground.
(c) Check that the magnetic clutch energized.
If operation is not as specified, replace the magnetic clutch.
I12998
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AC12
AIR CONDITIONING

AC1GB03
COMPONENTS
Suction Hose
Compressor
10 (100, 7)
Discharge Hose
z ORing
25 (250, 18)
Drive Belt
x5
10 (100, 7)
1AZFSE Engine:
Suction Hose
z ORing
Discharge Hose
z ORing
Compressor
25 (250, 18)
Drive Belt
25 (250, 18)
x5
z Nonreusable part

I18811
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AC13
AIR CONDITIONING

AC2IP02
REMOVAL
1.
2.
3.
4.
5.
6.
RUN ENGINE AT IDLE SPEED WITH A/C ON FOR

APPROX. 10 MINUTES
STOP ENGINE
DISCONNECT NEGATIVE () TERMINAL CABLE
FROM BATTERY
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
REMOVE DRIVE BELT (See page AC3)
7.
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.
I12999
8.
(a)
(b)
(c)

REMOVE COMPRESSOR
Disconnect the wire harness clamp.
Remove the 3 bolts and compressor.
I13000
9.
(a)
(b)
(c)
1AZFSE Engine:
REMOVE COMPRESSOR
Disconnect the wire harness clamp.
Remove the 4 bolts and compressor.
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AC14
AIR CONDITIONING

AC39H01
INSTALLATION
1.
(a)
(b)

INSTALL COMPRESSOR
Install the compressor with 3 bolts.
Connect the connector.
I13000
2.
(a)
(b)
1AZFSE Engine:
INSTALL COMPRESSOR
Install the compressor with 4 bolts.
Connect the connector.
3.
(a)
CONNECT DISCHARGE AND SUCTION HOSES

Lubricate 2 new Orings with compressor oil and install
them to the hoses.
(b) Connect the both hoses with 2 bolts.
NOTICE:
Hose should be connected immediately after the caps have
been removed.
I12999
4.
INSTALL AND CHECK DRIVE BELT (See page

AC2, AC4)
5.
CONNECT NEGATIVE () TERMINAL CABLE TO BATTERY
6.
EVACUATE AIR FROM REFRIGERATION SYSTEM
CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 460 20 g (16.23 0.71 oz.)
7.
INSPECT FOR LEAKAGE OF REFRIGERANT
If there is leakage, check the tightening torque at the joints.
8.
INSPECT A/C OPERATION
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AC15
AIR CONDITIONING
AIR INLET SERVOMOTOR

AC39I01
COMPONENTS
Blower Unit
Air Duct
Engine (and ECT) ECU
Cowl Side Trim
Lower Finish Panel
No. 2 Under Cover
Blower Unit Case

Air Inlet Servomotor
I18810
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AC16
AIR CONDITIONING

AC39J01
REMOVAL
1.
2.
3.
4.
5.
6.
(a)
(b)
REMOVE FRONT DOOR SCUFF PLATE ON PASSENGER SIDE

REMOVE COWL SIDE TRIM ON PASSENGER SIDE
REMOVE NO. 2 UNDER COVER
REMOVE LOWER FINISH PANEL (See page BO8)
REMOVE ENGINE (and ECT) ECU
RHD Models Only:

REMOVE THEFT DETERRENT ECU
Remove the 2 screws and ECU.
I03586
7.
REMOVE AIR DUCT
Remove the 2 screws and duct.
I03585
8.
(a)
(b)
(c)
REMOVE BLOWER UNIT

Remove the bolt, screw and nut.
Remove the blower unit.
N04901
9.
REMOVE AIR INLET SERVOMOTOR
Remove the 3 screws and air inlet servomotor.
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AC17
AIR CONDITIONING

AC39K01
INSPECTION
REC
7
1.
LHD:
INSPECT AIR INLET SERVOMOTOR OPERATION
7 and negative () lead to terminal 1 and check that arm
turns to REC side smoothly.
If operation is not as specified, replace the servomotor.
I19376
(b)

7 and the negative () lead to terminal 3 and check that
the arm turns to FRS side smoothly.
FRS
7
I19377
2.
RHD:
INSPECT AIR INLET SERVOMOTOR OPERATION
turns to REC side smoothly.
REC
7
I18814
(b)

the arm turns to FRS side smoothly.
FRS
7
I18815
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AC18
AIR CONDITIONING

AC39L01
INSTALLATION
Installation is in the reverse order of removal (See page AC16).
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AC19
AIR CONDITIONING
AIR MIX SERVOMOTOR
AIR MIX SERVOMOTOR

AC39M01
REMOVAL
1.
REMOVE BLOWER UNIT (See page AC16)
2.
(a)
(b)
REMOVE AIR MIX SERVOMOTOR

Remove the 3 screws and air mix servomotor.
I19340
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AC20
AIR CONDITIONING
AIR MIX SERVOMOTOR

AC39N01
INSPECTION
7
1.
LHD:
INSPECT AIR MIX SERVOMOTOR OPERATION
the arm turns to WARM side smoothly.
WARM
I18817
(b)

turns to COOL side smoothly.
COOL
7
I18816
2.
7 6
LHD:
INSPECT AIR MIX POSITION SENSOR RESISTANCE
Measure resistance between terminals at servomotor arm each
position as shown in the chart.
5
1
WARM
COOL
7 6
Tester connection
Condition
Specified condition
31
Constant
4.2 7.8 k
51
Arm position at WARM
0.84 1.56 k
51
Arm position at COOL
3.36 6.24 k
If resistance is not as specified, replace the servomotor.
5
1
I19332
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AC21
AIR CONDITIONING
AIR MIX SERVOMOTOR
3.
7
RHD:
INSPECT AIR MIX SERVOMOTOR OPERATION
the arm turns to COOL side smoothly.
COOL
I18817
(b)

turns to WARM side smoothly.
WARM
7
I18816
4.
7 6
RHD:
INSPECT AIR MIX POSITION SENSOR RESISTANCE
5
3
COOL
WARM
7 6
Tester connection
Condition
Specified condition
31
Constant
4.2 7.8 k
53
Arm position at COOL
3.36 6.24 k
53
Arm position at WARM
0.84 1.56 k
5
3
I19333
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AC22
AIR CONDITIONING
AIR MIX SERVOMOTOR

AC39O01
INSTALLATION
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AC23
AIR CONDITIONING
AIR OUTLET SERVOMOTOR

AC39P01
REMOVAL
REMOVE AIR OUTLET SERVOMOTOR
(a) Disconnect the connector.
(b) Remove the 3 screws and air outlet servomotor.
I19341
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AC24
AIR CONDITIONING

AC39Q01
INSPECTION
DEF
1.
LHD:
INSPECT AIR OUTLET SERVOMOTOR OPERATION
turns to DEF side smoothly.
I19334
FACE
(b)

the arm turns to FACE side smoothly.
I19335
2.
LHD:
INSPECT AIR OUTLET POSITION SENSOR RESISTANCE
DEF
5 4 3
Tester connection
Condition
Specified condition
21
Constant
4.2 7.8 k
32
Arm position at DEF
3.49 6.47 k
32
Arm position at FACE
0.71 1.33 k

5 4 3
FACE
I19338
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AC25
AIR CONDITIONING
3.
RHD:
INSPECT AIR OUTLET SERVOMOTOR OPERATION
turns to DEF side smoothly.
DEF
I19336
(b)

the arm turns to FACE side smoothly.
FACE
I19337
4.
RHD:
INSPECT AIR OUTLET POSITION SENSOR RESISTANCE
FACE
5 4 3 1
Tester connection
Condition
Specified condition
21
Constant
4.2 7.8 k
31
Arm position at DEF
3.49 6.47 k
31
Arm position at FACE
0.71 1.33 k

5 4 3 1
DEF
I19339
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AC26
AIR CONDITIONING

AC39R01
INSTALLATION
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AC27
AIR CONDITIONING
AIR CONDITIONER CONTROL ASSEMBLY

AC39S01
COMPONENTS
Center Cluster Finish Panel
Bulb
A/C Control Assembly
I18087
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AC28
AIR CONDITIONING

AC39T01
: 6 Clips
REMOVAL
1.
(a)
REMOVE CENTER CLUSTER FINISH PANEL

Using a screwdriver, remove the cluster finish panel.
(b)
(c)
Remove the cluster finish panel shown in the illustration.

Disconnect the connecters.
H15310
H16288
2.
REMOVE A/C CONTROL ASSEMBLY
Remove the 4 screws and A/C control panel assembly.
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AC29
AIR CONDITIONING

AC39U01
INSTALLATION
1.
INSTALL A/C CONTROL ASSEMBLY
Install the A/C control panel assembly to the cluster finish panel
with the 4 screws.
: 6 Clips
2.
(a)
(b)
INSTALL CENTER CLUSTER FINISH PANEL

Connect the connectors.
Install the cluster finish panel.
H15310
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AC30
AIR CONDITIONING
AIR CONDITIONER AMPLIFIER

AC39V01
1.
2.
From back side:
REMOVE A/C CONTROL ASSEMBRY (See page

AC28)
INSPECT A/C AMPLIFIER CIRCUIT
A14
A15
I18812
Tester connection
Condition
Specified condition
IG ON. Ambient temp.: 25 C (77 F)
1.35 1.75 V
IG ON. Ambient temp.: 40 C (104 F)
0.85 1.25 V
IG ON. Room temp.: 25 C (77 F)
1.8 2.2 V
IG ON. Room temp.: 40 C (104 F)
0.85 1.25 V
IG ON. Solar sensor subject to electric light
1.0 V or more
IG ON. Solar sensor covered by cloth
Below 1.0 V
IG ON. Evaporator temp.: 0 C (32 F)
2.0 2.4 V
IG ON. Evaporator temp.: 15 C (59 F)
1.4 1.8 V
LOCK LOCKSG (A159 A1518)
Start engine. Compressor: Operate
4.5 5.5 V
TW GND (A157 A1412)
IG ON
Pulse generation
Start engine (idling). Magnetic clutch: ON
10 14 V
Start engine (idling). Magnetic clutch: OFF
Below 1.5 V
IG ON. Mode selector: FACE
3.5 4.5 V
IG ON. Mode selector: DEF
0.5 1.5 V
IG ON. Set temp.: MAX. COOL
3.5 4.5 V
IG ON. Set temp.: MAX. HOT
0.5 1.5 V
Always
1 or less
IG ON. Mode selector: Except FACE
Below 1.0 V
IG ON. Mode selector: FACE
10 14 V
IG ON. Mode selector: Except DEF
Below 1.0 V
IG ON. Mode selector: DEF
10 14 V
TAM TAMSG
TAM SG (A14
(A1418
18 A1414)
A14 14)
TR TRSG
TR SG (A147
(A14 7 A14
A143)
3)
TS TSS5
TS S5 (A1419
(A14 19 A14
A143)
3)
TE TESG
TE SG (A148
(A14 8 A1415)
A14 15)
MGC GND (A154

(A15 4 A1412)
A14 12)
TPM TPMSG
TPM SG (A1420
(A14 20 A1417)
A14 17)
TPM S5 TPMSG
TPMS5
TPM SG (A141
(A14 1 A1417)
A14 17)
TPMSG Body ground (A1417
Body ground)
AOF GND (A151
(A15 1 A1412)
A14 12)
AOD GND (152

(15 2 A1412)
A14 12)
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AC31
AIR CONDITIONING
AMC GND (A1510

(A15 10 A1412)
A14 12)
AMH GND (A1511

(A15 11 A1412)
A14 12)
HR GND (A144
(A14 4 A1412)
A14 12)
ILL GND (A14

ILL+
(A1422
22 A1412)
A14 12)
BLW GND (A145

(A14 5 A1412)
A14 12)
GND Body ground (A1412 Body
ground)
REC GND (A15
(A1517
17 A1412)
A14 12)
FRS GND (A15

(A1516
16 A1412)
A14 12)
IG GND (A1411
(A14 11 A1412)
A14 12)
IG ON. Set temp.: Except MAX. COOL
Below 1.0 V
IG ON. Set temp.: COOL
10 14 V
IG ON. set temp.: Except MAX. HOT
Below 1.0 V
IG ON. Set temp.: HOT
10 14 V
IG ON. Blower motor: Operate
Below 1.0 V
IG ON. Blower motor: Not operate
10 14 V
Light control switch: TAIL
10 14 V
Light control switch: OFF
0V
IG ON. Blower motor: Operate
Pulse generation
IG ON. Blower motor: Not operate
10 14 V
Always
1 or less
IG ON. Air inlet selector: RECIRCULATE
Below 0.7 V
IG ON. Air inlet selector: FRESH
10 14 V
IG ON. Air inlet selector: FRESH
Below 0.7 V
IG ON. Air inlet selector: RECIRCULATE
10 14 V
IG ON.
10 14 V
IG OFF.
0V
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CAUTION
This manual does not include all the necessary items about repair and service. This manual is made
for the purpose of the use for the persons who have special techniques and certifications. In the
cases that nonspecialized or uncertified technicians perform repair or service only using this manual or without proper equipment or tool, that may cause severe injury to you or other people around
and also cause damage to your customers vehicle.
In order to prevent dangerous operation and damages to your customers vehicle, be sure to follow
the instruction shown below.
S
Must read this manual thoroughly. It is especially important to have good understanding all the
contents written in the PRECAUTION of IN section.
The service method written in this manual is very effective to perform repair and service. When
performing the operations following the procedures using this manual, be sure to use tools specified and recommended. If using nonspecified or recommended tools and service method,
be sure to confirm safety of the technicians and any possibility of causing personal injury or
damage to the customers vehicle before starting the operation.
If part replacement is necessary, must replace the part with the same part number or equivalent
part. Do not replace it with inferior quality.
It is important to note that this manual contains various Cautions and Notices that must be
carefully observed in order to reduce the risk of personal injury during service or repair, or the
possibility that improper service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these Cautions and Notices are not exhaustive, because it is
important to warn of all the possible hazardous consequences that might result from failure to
follow these instructions.
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ID1
ALPHABETICAL INDEX
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ID2
ALPHABETICAL INDEX (A F)
A
Page
ABBREVIATIONS USED IN THIS MANUAL
(TERMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS WITH EBD & BA & TRC & VSC SYSTEM
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER AMPLIFIER . . . . . . . . . . . . . . . . . . .
AIR CONDITIONER CONTROL ASSEMBLY . . . . . . . . .
AIR CONDITIONING (PREPARATION) . . . . . . . . . . . . .
AIR CONDITIONING
(SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . . . . .
AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . .
AIR INLET SERVOMOTOR . . . . . . . . . . . . . . . . . . . . . . .
AIR MIX SERVOMOTOR . . . . . . . . . . . . . . . . . . . . . . . . .
AIR OUTLET SERVOMOTOR . . . . . . . . . . . . . . . . . . . . .
ANTILOCK BRAKE SYSTEM WITH ELECTRONIC
BRAKE FORCE DISTRIBUTION (EBD)
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATF TEMPERATURE SENSOR (U240E) . . . . . . . . . . . .
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSAXLE SYSTEM (A246E) . . . . . . . .
AUTOMATIC TRANSAXLE SYSTEM (U240E) . . . . . . . .
AUTOMATIC TRANSAXLE UNIT (A246E) . . . . . . . . . . .
AUTOMATIC TRANSAXLE UNIT (U240E) . . . . . . . . . . .
IN35
DI169
AC30
AC27
PP44
SS33
AC1
AC15
AC19
AC23
DI127
AX4
BE16
DI1
PP22
SS19
DI60
PP27
SS23
AX1
AX1
AX28
AX33
B
BODY (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY (SERVICE SPECIFICATIONS) . . . . . . . . . . . . . . .
BODY ELECTRICAL (PREPARATION) . . . . . . . . . . . . . .
BRAKE (SERVICE SPECIFICATIONS) . . . . . . . . . . . . . .
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PP43
SS32
PP41
SS29
BR1
CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR AND MAGNETIC CLUTCH . . . . . . . . .
CUSTOMER PROBLEM ANALYSIS CHECK
(ABS WITH EBD & BA & TRC & VSC SYSTEM)
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(ANTILOCK BRAKE SYSTEM WITH ELECTRONIC
BRAKE FORCE DISTRIBUTION (EBD))
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(AUTOMATIC TRANSAXLE (A246E))
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(AUTOMATIC TRANSAXLE (U240E))
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(ENGINE IMMOBILISER SYSTEM)
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI170
DI128
DI2
DI61
DI256
D
DIAGNOSTIC TROUBLE CODE CHART
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE (C50, C250) . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE (E351) . . . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL CASE (S54, S55) . . . . . . . . . . . . . . . . . .
DIFFERENTIAL OIL SEAL (A246E) . . . . . . . . . . . . . . . . .
DIFFERENTIAL OIL SEAL (U240E) . . . . . . . . . . . . . . . .
DOUBLE LOCKING SYSTEM . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C
CIRCUIT INSPECTION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT INSPECTION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT INSPECTION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT INSPECTION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT INSPECTION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH (PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH (SERVICE SPECIFICATIONS) . . . . . . . . . . . .
CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
CL9
BE1
AC11
DI176
DI132
DI15
DI74
DI259
MX38
MX38
MX35
AX7
AX12
BE11
AC2
SR1
E
DI182
ENGINE IMMOBILISER SYSTEM

(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI255
F
DI136
DI23
DI82
DI264
BO1
PP1
SS4
CL3
CL1

(A246E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(U240E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(A246E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(U240E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . .
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AX11
AX16
AX20
AX25
IN9
BO4
SA1
SA13
ID3
ALPHABETICAL INDEX (G R)
N
Page
GENERAL INFORMATION
(HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS) . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(HOW TO USE THIS MANUAL) . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . .
NEUTRAL START SWITCH (A246E) . . . . . . . . . . . . . . . .

NEUTRAL START SWITCH (U240E) . . . . . . . . . . . . . . .
Page
AX3
AX6
IN19
IN1
IN4
OUTPUT SHAFT (C50, C250) . . . . . . . . . . . . . . . . . . . . .

OUTPUT SHAFT (E351) . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTPUT SHAFT (S54, S55) . . . . . . . . . . . . . . . . . . . . . .
MX30
MX29
MX27
H
HOW TO PROCEED WITH TROUBLESHOOTING
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO TROUBLESHOOT ECU
CONTROLLED SYSTEMS . . . . . . . . . . . . . . . . . . . . . .
HOW TO USE THE DIAGNOSTIC CHART AND
INSPECTION PROCEDURE
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . .
P
DI169
DI127
DI1
DI60
DI255
IN20
IN19
IN30
IN1
I
IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . .
INPUT SHAFT (C50, C250) . . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT (E351) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INPUT SHAFT (S54, S55) . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN3
MX23
MX23
MX19
BO5
M
MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (C50, C250)
(PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(PREPARATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY (C50, C250) . . . . .
MANUAL TRANSAXLE ASSEMBLY (E351) . . . . . . . . . .
MANUAL TRANSAXLE ASSEMBLY (S54, S55) . . . . . .
MANUAL TRANSAXLE UNIT (C50, C250) . . . . . . . . . . .
MANUAL TRANSAXLE UNIT (E351) . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE UNIT (S54, S55) . . . . . . . . . . . .
AC5
PP3
SS6
PP10
SS10
PP16
SS15
MX8
MX9
MX8
MX2
MX2
MX2
PARTS LOCATION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LOCATION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LOCATION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LOCATION
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARTS LOCATION (ENGINE IMMOBILISER SYSTEM)
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER DOOR LOCK CONTROL SYSTEM . . . . . . . . .
POWER STEERING FLUID . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING VANE PUMP (1AZFSE) . . . . . . .
(1ZZFE, 3ZZFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECHECK
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECHECK
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECHECK (AUTOMATIC TRANSAXLE (A246E))
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECHECK (AUTOMATIC TRANSAXLE (U240E))
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECHECK (ENGINE IMMOBILISER SYSTEM)
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION (FOR ALL OF VEHICLES) . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI178
DI133
DI16
DI76
DI260
BE4
SR2
SR19
SR8
DI171
DI129
DI3
DI62
DI257
IN9
DI181
DI135
DI18
DI79
DI263
R
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .
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AC8
IN4
ID4
ALPHABETICAL INDEX (S V)
S
SHIFT AND SELECT LEVER SHAFT (C50, C250) . . . .
SHIFT AND SELECT LEVER SHAFT (E351) . . . . . . . . .
SHIFT AND SELECT LEVER SHAFT (S54, S55) . . . . .
(C50, C250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT LEVER AND CONTROL CABLE (E351) . . . . . . .
(S54, S55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT LOCK SYSTEM (A246E) . . . . . . . . . . . . . . . . . . . .
SHIFT LOCK SYSTEM (U240E) . . . . . . . . . . . . . . . . . . .
SPEED SENSOR (U240E) . . . . . . . . . . . . . . . . . . . . . . . .
SRS AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD BOLT (SERVICE SPECIFICATIONS) . . . .
STEERING (PREPARATION) . . . . . . . . . . . . . . . . . . . . . .
STEERING (SERVICE SPECIFICATIONS) . . . . . . . . . .
SUSPENSION AND AXLE (PREPARATION) . . . . . . . . .
SUSPENSION AND AXLE
Page
MX37
MX37
MX34
MX45
MX45
MX42
AX8
AX13
AX3
BO3
SS1
PP37
SS30
PP32
SS27
T
TERMINALS OF ECU
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINALS OF ECU
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINALS OF ECU
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINALS OF ECU
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMINALS OF ECU
(DIAGNOSTICS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TILT STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . .
(A246E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(U240E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING (C50, C250) . . . . . . . . . . . . . . . .
TROUBLESHOOTING (E351) . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING (S54, S55) . . . . . . . . . . . . . . . . . .
DI179
DI134
DI17
DI77
DI261
IN35
SR6
AX33
AX38
MX1
MX1
MX1
V
VALVE BODY ASSEMBLY (A246E) . . . . . . . . . . . . . . . . .
VALVE BODY ASSEMBLY (U240E) . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION AND ENGINE SERIAL
NUMBER (IDENTIFICATION INFORMATION) . . . . .
VEHICLE LIFT AND SUPPORT LOCATIONS
(REPAIR INSTRUCTIONS) . . . . . . . . . . . . . . . . . . . . .
AX4
AX8
IN3
IN7
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INTRODUCTION
PREPARATION
SERVICE SPECIFICATIONS
DIAGNOSTICS
CLUTCH
C50, C250 MANUAL TRANSAXLE
E351 MANUAL TRANSAXLE
S54, S55 MANUAL TRANSAXLE
A246E AUTOMATIC TRANSAXLE
U240E AUTOMATIC TRANSAXLE
SUSPENSION AND AXLE
BRAKE
STEERING
BODY ELECTRICAL
BODY
AIR CONDITIONING
ALPHABETICAL INDEX
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INTRODUCTION
HOW TO USE THIS MANUAL . . . . . . . . . . . . .
IN1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . .
IN1
IDENTIFICATION INFORMATION . . . . . . . . . .
IN3
VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . .
IN3
REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . .
IN4
IN4
VEHICLE LIFT AND

SUPPORT LOCATIONS . . . . . . . . . . . . . . . . . .
IN7
FOR ALL OF VEHICLES . . . . . . . . . . . . . . . . . .
IN9
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN9
HOW TO TROUBLESHOOT
ECU CONTROLLED SYSTEMS . . . . . . . . .
IN19
IN19
HOW TO PROCEED WITH

IN20
HOW TO USE THE DIAGNOSTIC CHART

AND INSPECTION PROCEDURE . . . . . . . . . .
IN30
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IN35
ABBREVIATIONS USED IN THIS MANUAL . . . .
IN35
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IN1
INTRODUCTION
HOW TO USE THIS MANUAL

IN00U65
GENERAL INFORMATION
1.
INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2.
PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3.
TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN20.
Be sure to read this before performing troubleshooting.
4.
PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
Filler Cap
Float
Clevis Pin
z Gasket
Reservoir Tank
Boot
z Grommet
Slotted Spring Pin
Clip
12 (120, 9)
Clevis
15 (155, 11)
Snap Ring
Washer
Lock Nut
Push Rod
Piston
Cylinder
z Nonreusable part
N17080
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IN2
INTRODUCTION
The procedures are presented in a stepbystep format:

S
The illustration shows what to do and where to do it.
S
The task heading tells what to do.
S
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example
Task heading : what to do
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a) Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration.
SST 0935030020 (0935006120)
Illustration:
what to do and where
Set part No.

Detailed text :
Component part No.

how to do task
(b) Measure the stroke applying and releasing the compressed

air (392 785 kPa, 4 8 kgf/cm 2 or 57 114 psi) as shown
in the illustration.
Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in.)
Specification
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type.
6.
REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7.
SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick reference.
8.
CAUTIONS, NOTICES, HINTS:
S
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
S
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
S
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9.
SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
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IN3
INTRODUCTION
IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
IN06B11
VEHICLE IDENTIFICATION AND

ENGINE SERIAL NUMBER
B
B02393
1.
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped in the engine
compartment. This number has also been stamped on the
manufacturer s label.
A: Vehicle Identification Number
B: Manufacturers Label
2.
ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
1AZFSE engine:
1ZZFE, 3ZZFE engines:
3SFE engine:
1CDFTV engine:
B12481
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IN4
INTRODUCTION
REPAIR INSTRUCTIONS
REPAIR INSTRUCTIONS
IN03Z03
GENERAL INFORMATION
FI1066
BASIC REPAIR HINT

(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative () terminal cable from the battery.
(2) If it is necessary to disconnect the battery for inspection or repair, first disconnect the negative ()
terminal.
(3) When disconnecting the terminal cable, to prevent
damage to the battery terminal, loosen the cable
nut and raise the cable straight up without twisting
or prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or other abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut and tighten the nut after installation. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Nonreusable parts
(1) Always replace cotter pins, gaskets, Orings and oil
seals, etc. with new ones.
(2) Nonreusable parts are indicated in the component
illustrations by the z symbol.
(f)
Precoated parts
Precoated parts are bolts and nuts, etc. that are coated
with a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
(3) Precoated parts are indicated in the component illustrations by the L symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
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IN5
INTRODUCTION
(h)
(i)
Medium Current Fuse and High Current Fuse

Equal Amperage Rating
(j)
REPAIR INSTRUCTIONS
Carefully observe all specifications for bolt tightening

torques. Always use a torque wrench.
Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use
one with a lower rating.
BE1367
Illustration
Symbol
Part Name
Abbreviation
FUSE
FUSE
MEDIUM CURRENT FUSE
MFUSE
HIGH CURRENT FUSE
HFUSE
FUSIBLE LINK
FL
CIRCUIT BREAKER
CB
V00076
(k)
Care must be taken when jacking up and supporting the

vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN7).
(1) If the vehicle is to be jacked up only at the front or
rear end, make sure to place the stopper under the
wheels at the opposite end to block them in order to
ensure safety.
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IN6
INTRODUCTION
REPAIR INSTRUCTIONS
(2)
(l)
WRONG
CORRECT
IN0253
WRONG
CORRECT
IN0252
(m)
Example
(n)
IN0002
After the vehicle is jacked up, be sure to support it

on stands. It is extremely dangerous to do any work
on a vehicle raised on a jack alone, even for a small
job that can be finished quickly.
Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electricity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the connector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the electronic components, air filter and emissionrelated
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(7) When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a stepdown
adapter for adjustment. Once the hose has been
stretched, it may leak air.
Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected to.
(2) After completing a job, double check that the vacuum hoses are properly connected. A label under the
hood shows the proper layout.
Unless otherwise stated, all resistance is measured at an
ambient temperature of 20C (68F). Because the resistance may be outside specifications if measured at high
temperatures immediately after the vehicle has been running, measurement should be made when the engine has
cooled down.
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IN7
INTRODUCTION
REPAIR INSTRUCTIONS
IN04006
VEHICLE LIFT AND SUPPORT LOCATIONS
Front
JACK POSITION
Front
Front center member
Rear
Rear suspension member
CAUTION : When jackingup the rear and front, make sure the car is not
carrying any extra weight.
PANTOGRAPH JACK POSITION
SUPPORT POSITION
Safety stand and swing arm type lift
B02394
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IN8
INTRODUCTION
REPAIR INSTRUCTIONS
PLATE TYPE LIFT
B
Attachment
HINT :
Left and right set position
Place the vehicle over the center of the lift.
Front and rear set position
D Align the cushion gum ends of the plate

with the attachment lower ends (A, C).
D Align the attachment upper end (B) with the
front jack supporting point ().
Attachment dimensions
85 mm (3.35 in)
70 mm (2.76 in)
100 mm (3.94 in)

200 mm (7.87 in)
B02395
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IN9
INTRODUCTION
FOR ALL OF VEHICLES
FOR ALL OF VEHICLES

IN0HV01
PRECAUTION
1.
(a)
Negative Cable
BO4111
(b)
FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND

SEAT BELT PRETENSIONER
The AVENSIS/CORONA is equipped with an SRS (Supplemental Restraint System), such as the driver airbag,
front passenger airbag, side airbags, curtain shield airbag
and seat belt pretensioners.
Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the correct procedure described in this manual.
GENERAL NOTICE
(1) Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the battery (See Pub. No. RM599E,
page DI152).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the LOCK position and the negative () terminal cable is disconnected from the battery.
(The supplemental restraint system is equipped
with a backup power source so that if work is
started within 90 seconds of disconnecting the negative () terminal cable from the battery, the SRS
may deploy.)
When the negative () terminal cable is disconnected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is finished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle.
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IN10
INTRODUCTION
FOR ALL OF VEHICLES
(3)
Even in cases of a minor collision where the SRS

does not deploy, the steering wheel pad (See Pub.
No. RM599E, page RS15), front passenger airbag
assembly (See Pub. No. RM599E, page RS28),
side airbag assemblies (See Pub. No. RM698E,
page RS11), curtain shield airbag assemblies
(See Pub. No. RM698E, page RS25) and seat belt
pretensioners (See Pub. No. RM599E, page
BO152) should be inspected.
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be applied to the sensor during repairs.
(6) Never disassemble and repair the airbag sensor assembly, side airbag sensor assembly, steering
wheel pad, front passenger airbag, side airbag or
seat belt pretensioner in order to reuse them.
(7) If the airbag sensor assembly, side airbag sensor
assembly, steering wheel pad, front passenger airbag, side airbag or seat belt pretensioner have
been dropped, or if there are cracks, dents or other
defects in the case, bracket or connector, replace
them with new ones.
(8) Do not directly expose the airbag sensor assembly,
side airbag sensor assembly, steering wheel pad,
front passenger airbag, side airbag or seat belt pretensioner to hot air or flames.
(9) Use a volt/ohmmeter with high impedance (10 k/V
minimum) for troubleshooting of the electrical circuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work on the supplemental restraint system is
completed, check the SRS warning light (See Pub.
No. RM599E, page DI152).
(c)
Match marks
SPIRAL CABLE (in Combination Switch)

The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result.
Refer to Pub. No. RM599E, page SR18 of this manual
concerning correct steering wheel installation.
R11910
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IN11
INTRODUCTION
(d)
FOR ALL OF VEHICLES
STEERING WHEEL PAD (with Airbag)

(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface facing up.
Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag inflates for some reason. In addition do not store a
steering wheel pad on top of another one.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be applied to the steering wheel
pad and the pad should not be cleaned with detergents of any kind.
(4) Store the steering wheel pad where the ambient
temperature remains below 93C (200F), without
high humidity and away from electrical noise.
(5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the
steering column near the combination switch connector before starting work.
(6) When disposing of a vehicle or the steering wheel
pad alone, the airbag should be deployed using an
SST before disposal (See Pub. No. RM599E, page
RS17).
Carry out the operation in a safe place away from
electrical noise.
Example:
Correct
Wrong
B02401
Example:
Z13950
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IN12
INTRODUCTION
(e)
FOR ALL OF VEHICLES
FRONT PASSENGER AIRBAG ASSEMBLY

(1) Always store a removed or new front passenger airbag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deployment direction facing down could cause a serious
accident if the airbag inflates.
dangerous.)
(3) Grease should not be applied to the front passenger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly where the ambient temperature remains below 93C (200F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on
the assembly before starting work.
(6) When disposing of a vehicle or the airbag assembly
alone, the airbag should be deployed using an SST
before disposal (See Pub. No. RM599E, page
RS30).
Perform the operation in a safe place away from
electrical noise.
Example:
Correct
Wrong
B02402
Example:
B02404
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IN13
INTRODUCTION
(f)
Example:
FOR ALL OF VEHICLES
SIDE AIRBAG ASSEMBLY

(1) Always store a removed or new side airbag assembly with the airbag deployment direction facing up.
Storing the airbag assembly with the airbag deployment direction facing down could cause a serious
accident if the airbag inflates.
dangerous.)
(3) Grease should not be applied to the side airbag assembly and the surface should not be cleaned with
detergents of any kind.
(5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the
seat before starting work.
(6) When disposing of a vehicle or the side airbag assembly alone, the airbag should be deployed using
an SST before disposal (See Pub. No. RM698E,
page RS12).
electrical noise.
Correct
Wrong
B02129
Example:
B01546
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IN14
INTRODUCTION
FOR ALL OF VEHICLES
(g)
CURTAIN SHIELD AIRBAG ASSEMBLY

(1) Always store a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in
a safe place.
NOTICE:
Protection bag is not reuse.
CAUTION:
Never disassemble the curtain shield airbag assembly.
(2) Never measure the resistance of the airbag squib
dangerous.).
(3) Grease should not be applied to the curtain shield
airbag assembly and the surface should not be
cleaned with detergents of any kind.
(5) When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) into the
instrument panel before starting work.
(6) When disposing of a vehicle or the curtain shield airbag assembly alone, the airbag should be deployed
using an SST before disposal (See Pub. No.
RM698E, page RS26).
electrical noise.
Example:
Correct
Clear Plastic Bag
H11622 H12060
Wrong
B08604
Example:
B08605
H12059R06952
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IN15
INTRODUCTION
(h)
(i)
(j)
FOR ALL OF VEHICLES
SEAT BELT PRETENSIONER

(1) Never measure the resistance of the seat belt pretensioner. (This may cause the pretensioner operates, which is very dangerous.)
(2) Oil or water should not be put on the front seat outer
belt and the front seat outer belt should not be
cleaned with detergents of any kind.
(3) Store the front seat outer belt where the ambient
temperature remains below 80C (176F), without
high humidity and away from electrical noise.
(4) When using electric welding, first disconnect the
connector (yellow color and 2 pins) installed at the
center pillar lower garnish before starting work.
(5) When disposing of a vehicle or a front seat outer
belt alone, the seat belt pretensioner should be activated before disposal (See Pub. No. RM599E,
page BO153). Perform the operation in a safe
place away from electrical noise.
AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause
undesired ignition of the supplemental restraint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the LOCK position and the negative () terminal cable is disconnected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness and the cowl wire harness assembly
and floor wire harness assembly. The wires for the SRS
wire harness are encased in a yellow corrugated tube. All
the connectors for the system are also a standard yellow
color. If the SRS wire harness becomes disconnected or
the connector becomes broken due to an accident, etc.,
repair or replace it as shown on Pub. No. RM599E, page
RS65.
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IN16
INTRODUCTION
FOR ALL OF VEHICLES
2.
FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f)
Avoid coasting with ignition turned off and prolonged braking.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3.
IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as twoway radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicles electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicles electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Do not wind the antenna feeder together with the other wiring as much as possible, also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4.
FOR USING HANDHELD TESTER
CAUTION:
Observe the following items for safety reasons:
S
Before using the handheld tester, the handheld testers operator manual should be read thoroughly.
S
Be sure to route all cables securely when driving with the handheld tester connected to the
vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)
S
Two persons are required when test driving with the handheld tester, one person to drive the
vehicle and the other person to operate the handheld tester.
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IN17
INTRODUCTION
FOR ALL OF VEHICLES
5.
FOR VEHICLES EQUIPPED WITH POWER WINDOW CONTROL SYSTEM
When the battery is disconnected or the power to the window regulator motor is cut, the power window control system does not operate. It is necessary to initialize the system in the following procedures. Otherwise
window cannot be operated normally.
(1) Close window to the highest position.
(2) Keep holding the switch for 5 seconds.
(3) Check that automatic operation works. If not, repeat the above procedures.
6.
FOR VEHICLES EQUIPPED WITH SLIDING ROOF SYSTEM
Sliding roof stop position might be required to be initialized when battery failures (such as battery disconnection, connector disconnection and the voltage drop) are detected while the system is in operation. This also
occurs when rotating the motor with the battery disconnected. Sliding roof initialization can be done by the
following procedures.
(1) Operate the roof up to the maximum tilt position.
(2) Release the switch, and push it again in the same direction. (After 10 seconds have elapsed,
initialization begins.)
(3) The roof starts automatic operation if holding the switch, completes full one cycle (tilt down, slide
open, slide close and tilt up) of travel. Do not release the switch until the roof stops.
(4) Check that the roof stops at the correct position.
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IN18
INTRODUCTION
FOR ALL OF VEHICLES
7.
FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRC) & VEHICLE STABILITY CONTROL (VSC)
SYSTEM
NOTICE:
S
When replacing the steering angle sensor or ECU, or
when adjusting the front wheel alignment or steering
wheel center point in accordance with the removing
and installing or replacing the suspension, axle, or
steering parts, make sure to perform the steering
angle sensor zero point calibration (See page
DI171).
S
Do not remove or install the VSC related parts unless
necessary. Otherwise, there is a possibility that the
setting of the VSC to be affected.
S
When working on the VSC related operation, make
sure to check that the preparations before and after
work are completed according to the following
instruction.
S
When using a drum tester such as a speedometer tester or chassis dynamometer, etc., or jacking up the
front wheels and driving the wheels, always push in
the TRC & VSC cut (VSC OFF) switch and turn the
TRC & VSC system OFF.
(a) Press the VSC OFF switch.
(b) Check that the VSC OFF indicator light comes ON.
HINT:
The VSC OFF indicator light should be always OFF when the
engine is restarted.
F12737
(c)
Begin measurements.
(d)
Press the VSC OFF switch again to change the TRC &
VSC system to operational condition and check that the
VSC OFF indicator light goes off.
B12536
HINT:
S
S
The SLIP indicator light blinks when the TRC system is

operational.
The SLIP indicator light blinks and the VSC buzzer
sounds when the VSC system is operational.
F12737
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INTRODUCTION
HOW TO TROUBLESHOOT ECU CONTROLLED

SYSTEMS
IN19
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN00Z45
GENERAL INFORMATION
A large number of ECU controlled systems are used in the AVENSIS/CORONA. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and
expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic
knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the
problem. This manual is designed through emphasis of the above standpoint to help service technicians
perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems:
The troubleshooting procedure and how to make use of it are described on the following pages.
System
Page
1. Automatic Transaxle (A246E)
DI1
2. Automatic Transaxle (U240E)
DI60
3. AntiLock Brake System with Electronic Brake Force Distribution (EBD)
DI127
4. ABS with EBD & BA & TRC & VSC System
DI169
5. Engine Immobiliser System
DI255
FOR USING HANDHELD TESTER

S
Before using the handheld tester, the handheld testers operator manual should be read thoroughly.
S
If the handheld tester cannot communicate with ECU controlled systems when you have connected
the cable of the handheld tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operators
Manual.
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IN20
INTRODUCTION

SYSTEMS
IN06D10

Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in DI section, showing the most effective methods for each circuit.
Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that
circuit.
Vehicle Brought to Workshop
1
Ask the customer about the conditions and the
environment when the problem occurred.
Customer Problem
Analysis
Symptom Confirmation
and Diagnostic Trouble
Code Check
3
Symptom Simulation
2, 3
Confirm the symptoms and the problem conditions,
and check the diagnostic trouble codes.
(When the problem symptoms do not appear
during confirmation, use the symptom simulation
method described later on.)
Diagnostic Trouble
Code Chart
Problem Symptoms Table
Circuit Inspection or Parts

Inspection
Repair
Confirmation Test
End
4, 5, 6
Check the results obtained in Step 2, then confirm
the inspection procedure for the system or the part
which should be checked using the diagnostic
trouble code chart or the problem symptoms table.
7
Check and repair the affected system or part in
accordance with the instructions in Step 6.
8
After completing repairs, confirm that the problem
has been eliminated.
(If the problem is not reproduced, perform the
confirmation test under the same conditions and
in the same environment as when it occurred for
the first time.)
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INTRODUCTION
IN21

SYSTEMS
1.
CUSTOMER PROBLEM ANALYSIS
In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be
cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it
is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Important Point in the Problem Analysis:
The following 5 items are important points in the problem analysis. Past problems which are thought to be
unrelated and the repair history, etc. may also help in some cases, so as much information as possible should
be gathered and its relationship with the problem symptoms should be correctly ascertained for reference
in troubleshooting. A customer problem analysis table is provided in DI section for each system for your use.
Important Points in the Customer Problem Analysis
D What Vehicle model, system name
D When Date, time, occurrence frequency
D Where Road conditions
D Under what conditions? Running conditions, driving conditions, weather conditions
D How did it happen? Problem symptoms
(Sample) Supplemental restraint system check sheet.

Inspectors
Name
Supplemental Restraint System Check Sheet
Registration No.
/
Registration Year
Customers Name
Frame No.
Date Vehicle Brought In
km
miles
Odometer Reading
Date Problem First Occurred

Weather
Temperature
Vehicle Operation
/
Fine
Cloudy
Rainy
Snowy
/
Other
Approx.
Starting
Driving
Idling
Constant speed
Other
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Acceleration
Deceleration
]
IN22
INTRODUCTION

SYSTEMS
2.
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the AVENSIS/CORONA fulfills various functions. The first function is the Diagnostic
Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU
memory at the time of occurrence, to be output by the technician during troubleshooting. 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 down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the AVENSIS/CORONA.
Diagnostic Trouble
Code Check
Input Signal Check

(Sensor Check)
1. Automatic Transaxle (A246E)
f
(with check mode)
2. Automatic Transaxle (U240E)
f
(with check mode)
3. AntiLock Brake System with Electronic Brake Force Distribution (EBD)
4. ABS with EBD & BA & TRC & VSC System
5. Engine Immobiliser System
System
Diagnostic Test
Mode (Active Test)
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.
DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)
Diagnostic Trouble
Code Display
Confirmation
of Symptoms
Diagnostic Trouble
Code Check
Problem symptoms Same diagnostic

exist
trouble code is
displayed
Normal code is
displayed
Normal Code Display
Problem Condition
Problem is still occurring in the diagnostic
circuit
The problem is still occurring in a place
other than in the diagnostic circuit
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem)
No problem
symptoms exist
The problem occurred in the diagnostic

circuit in the past
Problem symptoms Normal code is

exist
displayed
The problem is still occurring in a place

other than in the diagnostic circuit
No problem
symptoms exist
The problem occurred in a place other

than in the diagnostic circuit in the past
Normal code is
displayed
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INTRODUCTION

SYSTEMS
IN23
Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the
diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble
code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic
trouble code troubleshooting or to troubleshooting of problem symptoms.
Diagnostic trouble code check
Making a note of and clearing of the diagnostic trouble codes displayed
Symptom confirmation
Problem symptoms
exist
No problem symptoms
exist
Simulation test using the symptom

simulation methods
Diagnostic trouble code check
D Diagnostic trouble code displayed

D Problem symptoms exist
D Normal code displayed

D Problem symptoms exist
Troubleshooting of problem indicated

by diagnostic trouble code
Troubleshooting of each
problem symptom
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D Normal code displayed

D No problem symptoms exist
System Normal
If a diagnostic trouble code was
displayed in the initial diagnostic
trouble code check, it indicates
that the trouble may have occurred
in a wire harness or connector in
that circuit in the past. Therefore,
check the wire harness and connectors (See page IN30).
IN24
INTRODUCTION

SYSTEMS
3.
SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customers vehicle. No matter how much experience a
technician has, or how skilled he or she may be, if he or she proceeds to troubleshoot without confirming
the problem symptoms he or she will tend to overlook something important in the repair operation and make
a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs
when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving,
etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in
that the external causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
Slightly shake the connector vertically and horizontally.
Shake Slightly
WIRE HARNESS
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thoroughly.
Swing Slightly
PARTS AND SENSOR
Vibrate Slightly
Apply slight vibration with a finger to the part of the sensor

considered to be the problem cause and check that the malfunction occurs.
HINT:
Applying strong vibration to relays may result in open relays.
V07268
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INTRODUCTION

SYSTEMS
HEAT METHOD: When the problem seems to occur when the suspect area is heated.
Heat the component that is the likely cause of the malfunction

with a hair dryer or similar object. Check to see if the malfunction
occurs.
M a l f u n ction
NOTICE:
(1) Do not heat to more than 60 C (140 F). (Temperature
is limited not to damage the components.)
(2) Do not apply heat directly to parts in the ECU.
IN25
WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a
highhumidity condition.
Sprinkle water onto the vehicle and check to see if the malfunction occurs.
NOTICE:
(1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front
surface.
(2) Never apply water directly onto the electronic components.
HINT:
If a vehicle is subject to water leakage, the leaked water may
contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken.
4
OTHER: When a malfunction seems to occur when electrical load is excessive.
Turn on all electrical loads including the heater blower, head

lights, rear window defogger, etc. and check to see if the malfunction occurs.
ON
B02389
B02390
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IN26
INTRODUCTION

SYSTEMS
4.
The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the
diagnostic trouble codes displayed. The Supplemental Restraint System diagnostic trouble code chart is
shown below as an example.
D DTC No.
Indicates the diagnostic trouble code.
D Page or Instructions
Indicates the page where the inspection procedure
for each circuit is to be found, or gives instructions
for checking and repairs.
D Trouble Area
Indicates the suspect area of the
problem.
D Detection Item
Indicates the system of the problem or
contents of the problem.

If a malfunction code is displayed during the DTC check, check the circuit listed for that code in the table
below. (Proceed to the page given for that circuit).
DTC No.
(See page)
Detection Item
ON
D Steering wheel pad (squib)

D Spiral cable
D Airbag sensor assembly
D Wire harness
ON

D Spiral cable
D Wire harness
ON

D Spiral cable
D Wire harness
ON
Front airbag sensor assembly (RH)

malfunction
D Front airbag sensor assembly (RH)

D Wire harness
ON
Front airbag sensor assembly (LH)

malfunction
D Front airbag sensor assembly (LH)

D Wire harness
ON
ON
airbag sensor assembly malfunction
Airbag sensor assembly
Short in P squib circuit (to ground)
D Front passenger airbag sensor assembly (squib)

Short in D squib circuit (to B))

12
(DI170)
Short in D squib circuit

13
(DI174)
Open in D squib circuit
14
(DI178)
16
SRS
Warming Light

D Spiral cable
D Wire harness
Short in D squib circuit (to ground)

11
(DI165)
15
(DI178)
Trouble Area
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ON
INTRODUCTION
IN27

SYSTEMS
5.
The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to
troubleshoot the problem when a Normal code is displayed in the diagnostic trouble code check but the
problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts
should be checked.
HINT:
When the problem is not detected by the diagnostic system even though the problem symptom is present,
it is considered that the problem is occurring outside the detection range of the diagnostic system, or that
the problem is occurring in a system other than the diagnostic system.
D Page
Indicates the page where the flow chart for each circuit
is located.
D Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.
D Problem Symptom
D Circuit or Part Name

Indicates the circuit or part which needs to be checked.

Proceed with troubleshooting of each circuit in the table below.
Symptom
Suspect Area
D With the ignition switch in the ACC or ON position, the SRS warning
light sometimes lights up after approx. 6 seconds have elapsed.
D SRS warning light is always lit up even when ignition switch is in
the LOCK position
See page
D SRS warning light circuit

(Always lights up when ignition switch is in
LOCK position.)
DI288
D With the ignition switch in the ACC or ON position, the SRS warning
light does not light up.
D SRS warning light circuit

(Dose not light up when ignition switch is turned to
ACC or ON.)
DI290
D DTC is not displayed.

D SRS warning light is always lit up at the time of DTC check
procedure.
D DTC is displayed without Tc and E1 terminal connection.
D Tc terminal circuit
DI294
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IN28
INTRODUCTION

SYSTEMS
6.
CIRCUIT INSPECTION
How to read and use each page is shown below.
D Diagnostic Trouble Code No. and Detection Item
D Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.
DTC
13
Short in D Squib Circuit
CIRCUIT DESCRIPTION
The D squib circuit consists of the airbag sensor assembly, spiral cable and steering wheel pad.
It causes the airbag to deploy when the airbag deployment conditions are satisfied.
For details of the function of each components,see OPERATION on page RS2.
DTC 13 is recorded when a short is detected in the D squib circuit.
DTC Detecting Condition
DTC No.
Trouble Area
SShort circuit between D) wire harness and D* wire harness of squib SSteering wheel pad (D squib)
SD squib malfunction
13
SSpiral cable
SSpiral cable malfunction
SAirbag sensor assembly
SAirbag sensor assembly malfunction
SWire harness
D Indicates the diagnostic trouble code, diagnostic

trouble code set parameter and suspect area of
the problem.
WIRING DIAGRAM
Airbag Sensor
Assembly
D Squib
GR
GY
A15
D+
A15
Spiral
Cable
D Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
R16015
B02407
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INTRODUCTION

SYSTEMS
D Indicates the position of the ignition switch during the check.
D Inspection Procedure
Use the inspection procedure to determine
if the circuit is normal or abnormal, and if it
is abnormal, use it to determine whether the
problem is located in the sensors, actuators,
wire harness or ECU.
ON
LOCK
Ignition Switch ON
Ignition Switch LOCK (OFF)

START
ACC
Ignition Switch ACC
Ignition Switch START
IN29
2
Check voltage at IG2 and ACC of airbag sensor assembly.

ON
Airbag Sensor Assembly
ACC
()
IG2
(+)
AB0119
W02766
H00041
PREPARATION:
CHECK:
Measure voltage between terminals IG2 and ACC of
airbag sensor assembly and body ground.
OK:
Voltage: Below 16V
Check battery and charging system.

(See charging system section)
NG
OK
D Indicates the place to check the voltage or resistance.

D Indicates the connector position to be checked, from the front or back side.
Wire Harness
Check from the connector front side. (without harness)
In this case, care must be taken not to bend the terminals.
Check from the connector back side.

(with harness)
D Indicates the condition of the connector of ECU during the check.

KNK
KNK
E6 Connector
E6 Connector
Connector being checked is connected.
Connector being checked is disconnected.
B00691
B00972
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IN30
INTRODUCTION

SYSTEMS
IN01138
HOW TO USE THE DIAGNOSTIC

CHART AND INSPECTION
PROCEDURE
1.
FI0046
FI0047
FI0048
CONNECTOR CONNECTION AND TERMINAL INSPECTION

S
For troubleshooting, diagnostic trouble code charts or
problem symptom charts are provided for each circuit with
detailed inspection procedures on the following pages.
S
When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be
normal in troubleshooting, then it is determined that the
problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to
Step 8 to replace the ECU. So always confirm that the
problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.
S
The instructions Check wire harness and connector and
Check and replace ECU which appear in the inspection
procedure, are common and applicable to all diagnostic
trouble codes. Follow the procedure outlined below
whenever these instructions appear.
OPEN CIRCUIT:
This could be due to a disconnected wire harness, faulty contact in the connector, and a connector terminal pulled out, etc.
HINT:
S
It is rarely the case that a wire is broken in the middle of
it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators
S
Faulty contact could be due to rusting of the connector
terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting
and reconnecting the connectors once changes the
condition of the connection and may result in a return to
normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector
check, but the problem disappears after the check, then
the cause is considered to be in the wire harness or connectors.
SHORT CIRCUIT:
This could be due to a contact between wire harness and the
body ground or to a short circuit occurred inside the switch, etc.
HINT:
When there is a short between the wire harness and body
ground, check thoroughly whether the wire harness is caught
in the body or is clamped properly.
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INTRODUCTION

SYSTEMS
IN31
2.
CONNECTOR HANDLING
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
FI7187
Sensor Side
3.
(a)
ECU Side
(b)
IN0379
CONTINUITY CHECK (OPEN CIRCUIT CHECK)

Disconnect the connectors at both ECU and sensor
sides.
Measure the resistance between the applicable terminals
of the connectors.
Resistance: 1 or less
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
ECU Side
Sensor Side
IN0378
4.
(a)
(b)
ECU Side
Sensor Side
IN0380
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
5.
(a)
(b)
Pull Lightly
Looseness of Crimping
IN0381
RESISTANCE CHECK (SHORT CIRCUIT CHECK)

Disconnect the connectors on both ends.
Measure the resistance between the applicable terminals
of the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.
Resistance: 1 M or higher
(c)
VISUAL CHECK AND CONTACT PRESSURE CHECK

Disconnect the connectors at both ends.
Check for rust or foreign material, etc. in the terminals of
the connectors.
Check crimped portions for looseness or damage and
check that the terminals are secured in lock portion.
HINT:
The terminals should not come out when pulled lightly from the
back.
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IN32
INTRODUCTION

SYSTEMS
(d)
Prepare a test male terminal and insert it in the female terminal, then pull it out.
NOTICE:
When testing a goldplated female terminal, always use a
goldplated male terminal.
HINT:
When the test terminal is pulled out more easily than others,
there may be poor contact in that section.
Fig. 1
ECU
Sensor
B
1
2
OPEN
1
1
2
2
A
1
2
6.
CHECK OPEN CIRCUIT
For the open circuit in the wire harness in Fig. 1, perform (a)
Continuity Check or (b) Voltage Check to locate the section.
Z17004
(a)
Fig. 2
ECU
C
1
2
Sensor
1
2
A
1
2
Z17005
Fig. 3
ECU
Sensor
C
1
2
B2
1
2
B1
1
2
A
1
2
B04722
Check the continuity.

(1) Disconnect connectors A and C and measure
the resistance between them.
In the case of Fig. 2:
Between terminal 1 of connector A and terminal 1
of connector C No continuity (open)
of connector C Continuity
Therefore, it is found out that there is an open circuit
between terminal 1 of connector A and terminal 1
of connector C.
(2) Disconnect connector B and measure the resistance between the connectors.
of connector B1 Continuity
Between terminal 1 of connector B2 and terminal
1 of connector C No continuity (open)
Therefore, it is found out that there is an open circuit
between terminal 1 of connector B2 and terminal
1 of connector C.
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INTRODUCTION

SYSTEMS
IN33
(b)
Fig. 4
Sensor
5V
A
C
5V B
1
1 1
2
2
2
0V
5V
Z17007
7.
CHECK SHORT CIRCUIT
If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a continuity check with ground.
Fig. 5
C SHORT B
1
1
2
2
Check the voltage.

In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check.
As shown in Fig. 4, with each connector still connected, measure the voltage between body ground
and terminal 1 of connector A at the ECU 5V output terminal, terminal 1 of connector B, and terminal 1 of connector C, in that order.
If the results are:
5V: 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 circuit in the wire harness between terminal 1 of B and terminal 1 of C.
A
1
2
Z17008
Fig. 6
ECU
Sensor
C
1
2
B
1
2
A
1
2
Z17009
Check the continuity with ground.

(1) Disconnect connectors A and C and measure
the resistance between terminal 1 and 2 of connector A and body ground.
Between terminal 1 of connector A and body
ground Continuity (short)
ground No continuity
Therefore, it is found out that there is a short circuit
between terminal 1 of connector A and terminal 1
of connector C.
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IN34
INTRODUCTION

SYSTEMS
(2)
Fig. 7
Sensor
C
1
2
B2
1
2
B1
1
2
A
1
2
ECU
Z17808
Disconnect connector B and measure the resistance between terminal 1 of connector A and body
ground, and terminal 1 of connector B2 and body
ground.
ground No continuity
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 AND REPLACE ECU
First check the ECU ground circuit. If it is faulty, repair it. If it is
normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear.
(1)
Measure the resistance between the ECU ground

terminal and the body ground.
Example
Ground
IN0383
(2)
ECU Side
Disconnect the ECU connector, check the ground

terminals on the ECU side and the wire harness
side for bend and check the contact pressure.
Ground
W/H Side
Ground
IN0384
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IN35
INTRODUCTION
TERMS
TERMS
IN04412
ABBREVIATIONS USED IN THIS MANUAL

Abbreviations
Meaning
ABS
AntiLock Brake System
A/C
Air Conditioner
AC
Alternating Current
ACC
Accessory
ACIS
Acoustic Control Induction System
ACSD
Automatic Cold Start Device
A.D.D.
Automatic Disconnecting Differential
AHC
Active Height Control Suspension
ALR
Automatic Locking Retractor
ALT
Alternator
AMP
Amplifier
ANT
Antenna
APPROX.
Approximately
A/T
Automatic Transmission (Transaxle)
ATF
Automatic Transmission Fluid
AUTO
Automatic
BACS
Boost Altitude Compensation System
BAT
Battery
B/L
BiLevel
BVSV
Bimetallic Vacuum Switching Valve
CB
Circuit Breaker
CD
Compact Disc
CH
Channel
CKD
Complete Knock Down
COMB.
Combination
CPE
Coupe
CRS
Child Restraint System
CTR
Center
DC
Direct Current
DIFF.
Differential
DIFF. LOCK
Differential Lock
DLC
Data Link Connector
DSP
Digital Signal Processor
DTC
Diagnostic Trouble Code
ECT
Electronic Control Transmission
ECU
Electronic Control Unit
EDU
Electronic Driving Unit
EFI
Electronic Fuel Injection
E/G
Engine
EGR
Exhaust Gas Recirculation
ELR
Emergency Locking Retractor
EVRV
Electronic Vacuum Regulating Valve
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IN36
INTRODUCTION
TERMS
FF
FrontEngineFrontWheelDrive
FIPG
Formed In Place Gasket
FL
Fusible Link
Fr
Front
FR
FrontEngineRearWheelDrive
FWD
FrontWheelDrive
GND
Ground
H/B
Hatchback
HI
High
HID
High Intensity Discharge (Head Lamp)
HT
Hard Top
HWS
Heated Windshield System
IAC
Idle Air Control
IFS
Independent Front Suspension
IG
Ignition
INT
Intermittent
I/P
Instrument Panel
IRS
Independent Rear Suspension
J/B
Junction Block
J/C
Junction Connector
LAN
Local Area Network
LB
Liftback
LCD
Liquid Crystal Display
LED
Light Emitting Diode
LH
LeftHand
LHD
LeftHand Drive
LO
Low
LSD
Limited Slip Differential
LSP & PV
Load Sensing Proportioning And Bypass Valve
LSPV
Load Sensing Proportioning Valve
MAP
Manifold Absolute Pressure
MAX.
Maximum
MIC
Microphone
MIL
Malfunction Indicator Lamp
MIN.
Minimum
MP
Multipurpose
MPI
Multipoint Electronic Fuel Injection
MPX
Multiplex Communication System
M/T
Manual Transmission
Neutral
No.
Number
O2S
Oxygen Sensor
O/D
Overdrive
OPT
Option
P & BV
Proportioning And Bypass Valve
PCS
Power Control System
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IN37
INTRODUCTION
TERMS
PKB
Parking Brake
PPS
Progressive Power Steering
PS
Power Steering
PTO
Power TakeOff
RAM
Random Access Memory
R/B
Relay Block
RBS
Recirculating Ball Type Steering
R/F
Reinforcement
RFS
Rigid Front Suspension
RH
RightHand
RHD
RightHand Drive
RLY
Relay
ROM
Read Only Memory
Rr
Rear
RR
RearEngine RearWheel Drive
RRS
Rigid Rear Suspension
RWD
RearWheel Drive
SDN
Sedan
SEN
Sensor
SICS
Starting Injection Control System
SPEC
Specification
SRS
Supplemental Restraint System
SSM
Special Service Materials
SST
Special Service Tools
STD
Standard
SW
Switch
SYS
System
T/A
Transaxle
TACH
Tachometer
TDC
Top Dead Center
TEMP.
Temperature
TEMS
TOYOTA Electronic Modulated Suspension
TFT
Toyota FreeTronic
T/M
Transmission
TMC
TOYOTA Motor Corporation
TRC
Traction Control System
U/D
Underdrive
VENT
Ventilator
VIN
Vehicle Identification Number
VSC
Vehicle Stability Control
VSV
Vacuum Switching Valve
w/
With
WGN
Wagon
W/H
Wire Harness
w/o
Without
1st
First
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IN38
INTRODUCTION
TERMS
2nd
Second
2WD
Two Wheel Drive Vehicle (4x2)
4WD
Four Wheel Drive Vehicle (4x4)
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PREPARATION
CLUTCH
MANUAL
MANUAL
MANUAL
................................
TRANSAXLE (C50, C250) . . . . . . . .
TRANSAXLE (E351) . . . . . . . . . . . . .
TRANSAXLE (S54, S55) . . . . . . . . .
PP1
PP3
PP10
PP16
AUTOMATIC TRANSAXLE (A246E) . . . . . . . .

AUTOMATIC TRANSAXLE (U240E) . . . . . . . .
SUSPENSION AND AXLE . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PP22
PP27
PP32
PP37
BODY ELECTRICAL . . . . . . . . . . . . . . . . . . . . .
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . .
PP41
PP43
PP44

Manual Name
Pub. No.
RM599E

RM698E
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PP1
PREPARATION
CLUTCH
CLUTCH
PP11902
SST (Special Service Tools)

0902300100
Union Nut Wrench 10 mm
Clutch line
0924963010
Torque Wrench Adaptor
LHD
Clutch line
0930100120
Clutch Guide Tool
0930100210
Clutch Guide Tool
0933300013
Clutch Diaphragm Spring Aligner
0992210010
Variable Open Wrench
http://vnx.su
Clutch accumulator
PP2
PREPARATION
CLUTCH
PP11A02
RECOMMENDED TOOLS
0903100030
Pin Punch .
0990500013
Snap Ring Pliers .
http://vnx.su
Reservoir tank
PP3
PREPARATION

PP11B02

0930800010
Oil Seal Puller
0930912020
5th Driven Gear Replacer
0931660011
Transmission & Transfer Bearing

Replacer
(0931600021)
0935032014
Output shaft front bearing
Output shaft rear ball bearing
Replacer A
TOYOTA Automatic Transmission

Tool Set
(0935132111)
Side Bearing Race Replacer
(0935132130)
Handle
(0935132150)
Oil Seal Replacer
Differential case oil seal
0955010013
Replacer Set B
Differential side bearing
(0925210010)
No. 1 Replacer Handle
(0955610011)
Differential Drive Pinion

Front Bearing Remover
0956432011
Differential Preload Adaptor
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PP4
PREPARATION
0960803071
Replacer
Input shaft rear ball bearing
0961265014
Steering Worm Bearing Puller
Input shaft front bearing

Differential side bearing outer race
0962862011
Ball Joint Puller
5th driven gear
0963620010
Upper Ball Joint Dust Cover

Replacer
No.3 hub sleeve assembly
0995000020
Bearing Remover
0995000030
Bearing Remover Attachment
0995030011
Puller A Set
No. 3 clutch hub
0995040011
Puller B Set
5th driven gear
(0995704010)
Attachment
0995060010
Replacer Set
(0995100230)
Replacer 23
5th driven gear
(0995100360)
Replacer 36
(0995100400)
Replacer 40
Input shaft front oil seal
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PP5
PREPARATION
(0995100460)
Replacer 46

(0995100620)
Replacer 62
0995060020
Replacer Set No.2
(0995100680)
Replacer 68

(Transaxle case side)
(0995100710)
Replacer 71

(Transmission case side)
0995070010
Handle Set
(0995107150)
Handle 150
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PP6
PREPARATION

PP04O03
RECOMMENDED TOOLS
0902500010
Torque Wrench (30 kgfcm)
0903100030
Pin Punch .
0904000011
Hexagon Wrench Set .
0904200010
Torx Socket T30 .
0990500012
Snap Ring No.1 Expander .
http://vnx.su
Differential preload
PP7
PREPARATION

PP04Q01
EQUIPMENT
Dial indicator with magnetic base
Feeler gauge
Micrometer
Torque wrench
Magnetic finger
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PP8
PREPARATION

PP04S01
LUBRICANT
Item
Manual transaxle oil
(w/ Differential oil)
Capacity
1 9 liters (2.0
1.9
(2 0 US qts,
qts 1.7
1 7 lmp.qts)
lmp qts)
http://vnx.su
Classification
API GL
GL4
4 or GL
GL5
5
SAE 75W90
PP9
PREPARATION

PP11C02
SSM (Special Service Materials)

0882600090
Seal Packing 1281,

THREE BOND 1281 or equivalent
(FIPG)
Transmission case x Transaxle case

Transmission case x Case cover
0883300080
Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalent
Transmission case cover bolt

Straight screw plug
Control shaft cover bolt
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PP10
PREPARATION

PP3D301

0922315020
Oil Seal & Bearing Replacer
0930800010
Oil Seal Puller
Output shaft front bearing outer

race
0931620011
Transfer Bearing Replacer
Differential case tapered roller

bearing
0931660011

Replacer
(0931600011)
Replacer Pipe
(0931600021)
Replacer A
(0931600041)
Replacer C
1st gear
No.1 hub sleeve
bearing outer race
Replacer F
0950630012
Differential Drive Pinion Rear

Bearing Cone Replacer
Output shaft rear bearing
0950635010

Bearing Replacer
No.2 hub sleeve

3rd gear
Input shaft rear bearing
(0931600071)
1st gear bearing inner race
0956432011
Differential case taperd roller

bearing preload
0960800081
Differential Side Bearing Cone

Replacer
Input shaft oil seal
http://vnx.su
PP11
PREPARATION
0961265014
Steering Worm Bearing Puller
Input shaft bearing

bearing outer race
0995000020
Bearing Remover
0995000030
0995030011
Puller A Set
5th driven gear

No.3 clutch hub
0995040011
Puller B Set
Differential case tapered roller bearing
(0995704010)
Attachment
Differential case taperd roller bearing

inner race
0995060010
Replacer Set
(0995100530)
Replacer 53

inner race
(0995100580)
Replacer 58
Input shaft bearing
(0995100450)
Replacer 45

inner race
0995060020
Replacer Set No.2
(0995100890)
Replacer 89
0995070010
Handle Set
http://vnx.su

outer race
PP12
PREPARATION
(0995107150)
Handle 150
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PP13
PREPARATION

PP0VD04
RECOMMENDED TOOLS
0902500010
0903100030
Pin Punch .
0904000011
0904200040
Torx Socket T50 .
0904200050
Torx Socket T45 .
0908200040
TOYOTA Electrical Tester.
0925800030
Hose Plug Set .
0990500012
0990500013
Snap Ring Pliers .
http://vnx.su
PP14
PREPARATION

PP0VE02
EQUIPMENT
Dial indicator with magnetic base
Feeler gauge
Magnetic finger
Micrometer
Plastigage
Precision straight edge
Torque wrench
Vise
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PP15
PREPARATION

PP0VF05
LUBRICANT
Item
Capacity
2.5 liters (2.6 US qts, 2.2 Imp. qts)
http://vnx.su
Classification
API GL4 or GL5
SAE 75W90
PP16
PREPARATION

PP0H207

0930800010
Oil Seal Puller

0930912020
5th Driven Gear Replacer
5th driven gear
0931035010
Countershaft Bearing Replacer

0931660011

Replacer
(0931600011)
Replacer Pipe
3rd driven gear

(0931600041)
Replacer C
Output shaft thrust washer
0935032014

Tool Set
(0935132120)
Overdrive Bearing Replacer
(0935132130)
Handle

retainer oil seal
(0935132150)
Oil Seal Replacer

retainer oil seal
0956432011
0960800071
Drive Pinion Rear Bearing Cone

Replacer
http://vnx.su
Input shaft rear bearing
PP17
PREPARATION
0960800081
Differential Side Bearing Cone

Replacer
Input shaft front oil seal
0961222011
Tilt Handle Bearing Replacer
Output shaft rear bearing

No.3 clutch hub
0995000020
Bearing Remover
0995000030
0995030011
Puller A Set
No. 3 clutch hub
0995040011
Puller B Set
5th driven gear
0995060020
Replacer Set No.2

retainer oil seal
outer race
(0995100680)
Replacer 68
0995070010
Handle Set
(0995107150)
Handle 150
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PP18
PREPARATION

PP11D02
RECOMMENDED TOOLS
0902500010
0903100030
Pin Punch .
0904000011
0990500012
http://vnx.su
PP19
PREPARATION

PP0H401
EQUIPMENT
Dial indicator
Torque wrench
Feeler gauge
Magnetic finger
Micrometer
http://vnx.su
PP20
PREPARATION

PP0H502
LUBRICANT
Item
Capacity
2.2 liters (2.3 US qts, 1.9 lmp. qts)
http://vnx.su
Classification
API GL4 or GL5
SAE 75W90
PP21
PREPARATION

PP11E02

0882600090
Seal Packing 1281,

(FIPG)

0883300070
Adhesive 1324,
Rear bearing retainer set bolt
0883300080
Adhesive 1344
THREE BOND 1344
Straight screw plug

Control shaft cover bolt
Lock ball assembly
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PP22
PREPARATION

PP2J602

0930800010
Oil Seal Puller
0935032014

Tool Set
(0935132010)
Oneway Clutch Test Tool
(0935132020)
Stator Stopper
(0935132111)
Side Bearing Race Replacer
(0935132130)
Handle
(0935132150)
Oil Seal Replacer
0999200095
Automatic Transmission Oil

Pressure Gauge Set
(0999200231)
Adaptor C
(0999200271)
Gauge Assy
http://vnx.su
PP23
PREPARATION

PP2J702
RECOMMENDED TOOLS
0908200040
http://vnx.su
PP24
PREPARATION

PP2J801
EQUIPMENT
Vernier calipers
Torque converter
Dial indicator or dial indicator with magnetic base
Drive plate
Straight edge
Torque converter
Torque wrench
http://vnx.su
PP25
PREPARATION

PP0IP02
LUBRICANT
Item
Automatic transmission fluid
Dry fill
Drain and refill
Capacity
Classification

ATF Dll or DEXRON lll (DEXRON ll)
http://vnx.su
PP26
PREPARATION

PP2J901

0883300080
Adhesive 1344
THREE BOND 1344
http://vnx.su
PP27
PREPARATION

PP2J603

0922300010
Cover & Seal Replacer
0930800010
Oil Seal Puller
0935032014

Tool Set
(0935132010)
Oneway Clutch Test Tool
(0935132020)
Stator Stopper
(0935132130)
Handle
(0935132150)
Oil Seal Replacer
0999200095
Automatic Transmission Oil

Pressure Gauge Set
(0999200231)
Adaptor C
(0999200271)
Gauge Assy
http://vnx.su
PP28
PREPARATION

PP2J703
RECOMMENDED TOOLS
0908200040
http://vnx.su
PP29
PREPARATION

PP2J801
EQUIPMENT
Vernier calipers
Torque converter
Dial indicator or dial indicator with magnetic base
Drive plate
Straight edge
Torque converter
Torque wrench
http://vnx.su
PP30
PREPARATION

PP0IP03
LUBRICANT
Item
Automatic transmission fluid
Dry fill
Drain and refill
Capacity
Classification

ATF Type TIV
http://vnx.su
PP31
PREPARATION

PP2J901

0883300080
Adhesive 1344
THREE BOND 1344
http://vnx.su
PP32
PREPARATION
SUSPENSION AND AXLE
SUSPENSION AND AXLE

PP3CN01

0924000020
Wire Gauge Set
Front drive shaft
0950635010

Bearing Replacer
Front drive shaft
0952001010
Drive Shaft Remover Attachment
Front drive shaft
0952024010
Differential Side Gear Shaft

Puller
Front drive shaft
(0952032040)
Shocker Set
0952124010
Drive Shaft Boot Clamping Tool
Front drive shaft
0960816042
Front Hub Bearing Adjusting Tool
Front drive shaft
(0960802021)
Bolt & Nut
(0960802041)
Retainer
0971030021
(0971003141)
0995000020
Suspension Bushing Tool Set
Front drive shaft
Bushing Remover Base
Bearing Remover
http://vnx.su
Front axle
Front drive shaft
PP33
PREPARATION
0995060010
Replacer Set
(0995100640)
Replacer 64
0995070010
Handle Set
(0995107150)
Handle 150
SUSPENSION AND AXLE
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Front axle
Front drive shaft
Front axle
Front drive shaft
PP34
PREPARATION
SUSPENSION AND AXLE

PP3CO01
RECOMMENDED TOOLS
0902500010
0990500012
0990500013
Snap Ring Pliers .
http://vnx.su
PP35
PREPARATION
SUSPENSION AND AXLE

PP11I03
EQUIPMENT
Dial indicator
Torque wrench
http://vnx.su
PP36
PREPARATION
SUSPENSION AND AXLE

PP11J03
LUBRICANT
Item
Outboard joint grease
Inboard joint grease
Capacity
Color=Black
Color=Yellow
85 105 g (3.00 3.70 oz.)

125.5 135.5 g (4.43 4.78 oz.)
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Application
PP37
PREPARATION
STEERING
STEERING
PP2JE03

0902312700
Union Nut Wrench 17mm
PS vane pump (1ZZFE, 3ZZFE)
0924963010
PS vane pump (1AZFSE)
0964010010
Power Steering Pressure Gauge

Set
(0964101010)
Gauge Assy
(0964101030)
Attachment B
(0964101060)
Attachment E
0995060010
Replacer Set
(0995100280)
Replacer 28
0995070010
Handle Set
(0995107100)
Handle 100
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PP38
PREPARATION
STEERING
PP2JF03
RECOMMENDED TOOLS
0902500010
http://vnx.su
PS vane pump
PP39
PREPARATION
STEERING
PP0J911
EQUIPMENT
Caliper gauge
PS vane pump
Vernier Calipers
PS vane pump
Feeler gauge
PS vane pump
Micrometer
PS vane pump
Torque wrench
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PP40
PREPARATION
STEERING
PP18M03
LUBRICANT
Item
Capacity
Classification

(Total)
0.8 liters (0.9 US qts, 0.7 Imp.qts)
ATF DEXRON II or III
http://vnx.su
PP41
PREPARATION
BODY ELECTRICAL
BODY ELECTRICAL
PP09004
RECOMMENDED TOOLS
0908200050
TOYOTA Electrical Tester Set.
http://vnx.su
PP42
PREPARATION
BODY ELECTRICAL
PP09104
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
http://vnx.su
PP43
PREPARATION
BODY
BODY
PP0M702
EQUIPMENT
Clip remover
Torque wrench
http://vnx.su
PP44
PREPARATION
AIR CONDITIONING
AIR CONDITIONING
PP3D001

0711058060
Air Conditioner Service Tool Set
(0711758060)
Refrigerant Drain Service Valve
(0711758070)
TJoint
(0711758080)
Quick Disconnect Adapter
High pressure side
(0711758090)
Quick Disconnect Adapter
Low pressure side
(0711788060)
Refrigerant Charging Hose
High pressure side

(Color: Red)
(0711788070)
Low pressure side

(Color: Blue)
(0711788080)
Utility
(Color: Green)
0711638360
Gas Leak Detector Assembly
0924963010
Drive belt (1AZFSE)
0987000015
A/C Quick Joint Puller No.1
Suction Tube
0987000025
A/C Quick Joint Puller No.2
Liquid Tube
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PP45
PREPARATION
AIR CONDITIONING
PP3D101
RECOMMENDED TOOLS
0908200040
http://vnx.su
PP46
PREPARATION
AIR CONDITIONING
PP09505
EQUIPMENT
Voltmeter
Ammeter
Ohmmeter
Test lead
Torque wrench
http://vnx.su
PP47
PREPARATION
AIR CONDITIONING
PP09602
LUBRICANT
Item
Compressor oil
Capacity
Classification
NDOIL 8 or equivalent
http://vnx.su
http://vnx.su
STANDARD BOLT . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSAXLE (C50, C250) . . . . . . . .
MANUAL TRANSAXLE (E351) . . . . . . . . . . . . .
SS1
SS4
SS6
SS10
MANUAL TRANSAXLE (S54, S55) . . . . . . . . .

SUSPENSION AND AXLE . . . . . . . . . . . . . . . .
SS15
SS19
SS23
SS27
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SS29
SS30
SS32
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . .
SS33

Manual Name
Pub. No.
RM599E

RM698E
http://vnx.su
http://vnx.su
SS1
STANDARD BOLT
STANDARD BOLT
SS0ZS01
HOW TO DETERMINE BOLT STRENGTH

Bolt Type
Hexagon Head Bolt
Normal Recess Bolt
Deep Recess Bolt
Stud Bolt
Weld Bolt
Class
4T
No Mark
No Mark
No Mark
5T
6T
w/ Washer
w/ Washer
7T
8T
9T
10
10T
11
11T
B06431
http://vnx.su
SS2
STANDARD BOLT
SS0ZT01
SPECIFIED TORQUE FOR STANDARD BOLTS

Specified torque
Class
Diameter
mm
Pitch
mm
Hexagon head bolt
Hexagon flange bolt
Nm
kgfcm
ftlbf
Nm
kgfcm
ftlbf
4T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
5
12.5
26
47
74
115
55
130
260
480
760
1,150
48 in.lbf
9
19
35
55
83
6
14
29
53
84
60
145
290
540
850
52 in.lbf
10
21
39
61
5T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
6.5
15.5
32
59
91
140
65
160
330
600
930
1,400
56 in.lbf
12
24
43
67
101
7.5
17.5
36
65
100
75
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.lbf
15
32
59
90
7T
6
8
10
12
14
16
1
1.25
1.25
1.25
1.5
1.5
10.5
25
52
95
145
230
110
260
530
970
1,500
2,300
8
19
38
70
108
166
12
28
58
105
165
120
290
590
1,050
1,700
9
21
43
76
123
8T
8
10
12
1.25
1.25
1.25
29
61
110
300
620
1,100
22
45
80
33
68
120
330
690
1,250
24
50
90
9T
8
10
12
1.25
1.25
1.25
34
70
125
340
710
1,300
25
51
94
37
78
140
380
790
1,450
27
57
105
10T
8
10
12
1.25
1.25
1.25
38
78
140
390
800
1,450
28
58
105
42
88
155
430
890
1,600
31
64
116
11T
8
10
12
1.25
1.25
1.25
42
87
155
430
890
1,600
31
64
116
47
97
175
480
990
1,800
35
72
130
http://vnx.su
SS3
STANDARD BOLT
SS0ZU01
HOW TO DETERMINE NUT STRENGTH

Nut Type
Present Standard
Hexagon Nut
Old Standard Hexagon Nut

Cold Forging Nut
Class
Cutting Processed Nut
4N
No Mark
5N (4T)
No Mark (w/ Washer)
No Mark (w/ Washer)
No Mark
6N
6N
7N (5T)
*
8N
8N
10N (7T)
10N
No Mark
11N
11N
12N
12N
*: Nut with 1 or more marks on one side surface of the nut.

B06432
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength classification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more
http://vnx.su
SS4
CLUTCH
CLUTCH
SS02L03
SERVICE DATA
Pedal height from asphalt sheet
3ZZFE LHD
RHD
1ZZFE Engine LHD
RHD
1AZFSE Engine LHD
RHD
139.7 149.7 mm (5.500 5.894 in.)

144.3 154.3 mm (5.681 6.075 in.)
139.7 149.7 mm (5.500 5.894 in.)
144.3 154.3 mm (5.681 6.075 in.)
148.3 158.3 mm (5.893 6.232 in.)
152.9 162.9 mm (6.020 6.413 in.)
Pedal freeplay
1.0 5.0 mm (0.039 0.197 in.)
Push rod play at pedal top
5.0 15.0 mm (0.197 0.591 in.)
Clutch release point from pedal full stroke end position
25 mm (0.98 in.) or more
Disc rivet head depth
Min. 0.3 mm (0.012 in.)
Disc runout
Max.
0.8 mm (0.031 in.)
Flywheel runout
Max
0.1 mm (0.004 in.)
Diaphragm spring finger wear
Max. depth
0.5 mm (0.020 in.)
Diaphragm spring finger wear
Max. width
6.0 mm (0.236 in.)
Max.
0.5 mm (0.020 in.)
Diaphragm spring tip nonalignment
http://vnx.su
SS5
CLUTCH
SS02M03
TORQUE SPECIFICATION
Part tightened
Nm
kgfcm
ftlbf
Clutch line union
15
155
11
Master cylinder installation nut
12
120
32 (44)
330 (450)
24 (33)
19
195
14
37
39
375
400
27
29
Master cylinder x Clutch accumulator
1CDFTV Engine RHD
Clutch cover x Flywheel

Release fork support
1ZZFE, 3ZZFE Engine

Others Engine
( ): For use without SST
http://vnx.su
SS6

SS02P06
SERVICE DATA
Input shaft roller bearing journal diameter
Min. 24.985 mm (0.9834 in.)
Input shaft 3rd gear journal diameter
Min. 30.985 mm (1.2199 in.)
Input shaft 4th gear journal diameter
Min. 28.985 mm (1.1411 in.)
Min. 24.885 mm (0.9797 in.)
Input shaft runout
Max.
Output shaft roller bearing journal diameter
Min. 32.985 mm (1.2986 in.)
0.03 mm (0.0012 in.)
Output shaft 1st gear journal diameter
Min. 37.985 mm (1.4955 in.)
Output shaft 2nd gear journal diameter
Min. 31.985 mm (1.2592 in.)
Output shaft runout
Max.
0.03 mm (0.0012 in.)
Gear thrust clearance
1st
STD
Max.
0.10 0.40 mm (0.0039 0.0157 in.)

0.40 mm (0.0157 in.)
2nd
STD
Max.
0.10 0.45 mm (0.0039 0.0177 in.)

0.45 mm (0.0177 in.)
3rd
STD
Max.
0.10 0.35 mm (0.0039 0.0138 in.)

0.35 mm (0.0138 in.)
4th
STD
Max.
0.10 0.55 mm (0.0039 0.0217 in.)

0.55 mm (0.0022 in.)
5th
STD
Max.
0.10 0.57 mm (0.0039 0.0244 in.)

0.57 mm (0.0224 in.)
Gear radial clearance
1st, 2nd, 3rd, 4th, and 5th (KOYO made)
STD
Max.
0.015 0.058 mm (0.0006 0.0023 in.)

0.058 mm (0.0023 in.)
1st, 2nd, 3rd, 4th, and 5th (NSK made)
STD
Max.
0.015 0.056 mm (0.0006 0.0022 in.)

0.056 mm (0.0022 in.)
No. 3 gear shift fork to No. 3 hub sleeve clearance
Max.
0.5 mm (0.020 in.)
No. 2 gear shift fork to No. 2 hub sleeve clearance
Max.
0.35 mm (0.014 in.)
No. 1 gear shift fork to reverse gear clearance
Max.
0.35 mm (0.014 in.)
Synchronizer ring to gear clearance
1st, 4th and 5th
Min. 0.75 mm (0.0295 in.)
3rd
Min. 0.65 mm (0.0256 in.)
2nd
Min. 0.70 mm (0.0276 in.)
Drive in de
depth
th
Control shaft cover oil seal
Transmission case oil seal
Transaxle case oil seal
Select inner lever slotted sspring
ring pin
in
No.1 shift inner lever slotted spring
g pin
No.2 shift inner lever slotted spring pin
1.0 2.0 mm (0.039 0.079 in.)

9.9 0.3 mm (0.390 0.012 in.)
1.9 0.3 mm (0.075 0.012 in.)
0 0.5 mm (0 0.020 in.)
0 0.5 mm ((0 0.020 in.))
3.5 0.5 mm (0.138 0.020 in.)
http://vnx.su
SS7
Input shaft snap ring thickness
No.2 clutch hub
Rear bearing
Output shaft snap ring thickness

No.1 clutch hub
No.3 clutch hub
Mark 0
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
2.30 mm (0.0906 in.)

2.36 mm (0.0929 in.)
2.42 mm (0.0953 in.)
2.48 mm (0.0976 in.)
2.54 mm (0.1000 in.)
2.60 mm (0.1024 in.)
2.29 mm (0.0902 in.)
2.35 mm (0.0925 in.)
2.41 mm ((0.0949 in.))
2.47 mm ((0.0972 in.))
2.53 mm (0.0996 in.)
2.59 mm (0.1020 in.)
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
2.50 mm (0.0984 in.)

2.56 mm (0.1008 in.)
2.62 mm (0.1031 in.)
2.68 mm (0.1055 in.)
2.74 mm (0.1079 in.)
2.80 mm (0.1102 in.)
2.25 mm (0.0886 in.)
2.31 mm (0.0909 in.)
2.37 mm ((0.0933 in.))
2.43 mm ((0.0957 in.))
2.49 mm (0.0980 in.)
2.55 mm (0.1004 in.)
2.61 mm (0.1028 in.)
Differential side bearing preload

reload (at starting)(For use with SST)
New bearing
Reused bearing
0.8 1.6 N
Nm
m (8 16 kgf
kgfcm,
cm, 6.9 13.9 in.
in.lbf)
lbf)
0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
Differential pinion to side gear backlash
0.05 mm 0.20 mm (0.0020 0.0079 in.)
Differential side gear thrust washer thickness
0.95 mm (0.0374 in.)

1.00 mm (0.0394 in.)
1.05 mm (0.0413 in.)
1.10 mm (0.0433 in.)
1.15 mm (0.0453 in.)
1.20 mm (0.0472 in.)
http://vnx.su
SS8
Differential side bearing adjusting shim thickness

Mark A
Mark B
Mark C
Mark D
Mark E
Mark F
Mark G
Mark H
Mark J
Mark K
Mark L
Mark M
Mark N
Mark P
Mark Q
Mark R
Mark S
Mark T
Mark U
2 10 mm (0.0827
2.10
(0 0827 in.)
in )
2
2.15
15 mm (0.0846
(0 0846 in.)
in )
2
2.20
20 mm (0.0866
(0 0866 in.)
in )
2
2.25
25 mm (0.0886
(0 0886 in.)
in )
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm ((0.1043 in.))
2.70 mm ((0.1063 in.))
2.75 mm ((0.1083 in.))
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
2.90 mm (0.1142 in.)
2.95 mm (0.1161 in.)
3.00 mm ((0.1181 in.))
http://vnx.su
SS9

SS02Q07
Part tightened
Nm
kgfcm
ftlbf
Clutch release cylinder x Transaxle
12
120
Starter x Transaxle
39
400
29
Transaxle x Engine
64
650
47
Stiffener plate set bolt (See page MX3)
Bolt B
Bolt A
47
23
480
230
35
17
Engine left mounting bracket x Transaxle
Bolt A
Nut B
52
87
530
890
38
64
Front wheel
216
2,200
159
Filler and Drain plugs
39
400
29
Front exhaust pipe x Exhaust manifold
62
630
46
Center exhaust pipe x Tail exhaust pipe
43
440
32
Front transport hook x Engine mounting center member
39
400
29
73
72
740
730
54
53
Engine rear mounting bracket x Insulator
87
890
64
29
300
22
Transmission case x Transmission case cover
18
185
13
Straight screw plug (Reverse restrict pin)
13
130
Straight screw plug
25
250
18
Transaxle case receiver x Transaxle case
11
115
Differential case x Ring gear
77
790
57
Transaxle case x Differential case
29
300
22
Reverse shift arm bracket set bolt
17
175
13
No.1, No.2, No.3 shift forks and shift head set bolt
16
160
12
Lock ball assembly (Reverse shift fork side)
39
400
29
Lock ball assembly (Shift and select lever shaft side)
29
300
22
Reverse idler gear shaft lock bolt
29
300
22
Rear bearing retainer x Transmission case
27
280
20
5th driven gear lock nut
118
1,200
87
Control shaft cover x Transmission case
20
200
14
Control shift lever x Dust boot
12
120
Selecting bellcrank assembly x Transaxle case
25
250
18
Control shaft assembly x Transaxle case
12
120
Oil receiver pipe set bolt
17
175
13
Control cable bracket x Transmission case
25
250
18
Backup light switch
40
410
30
Speed sensor lock plate set bolt
11
115
Clutch release fork support
37
375
27
Engine mounting center member (See page MX3)
Bolt A
Bolt B
http://vnx.su
SS10

SS0G606
SERVICE DATA
Input shaft
3rd & 4th gear journal diameter
5th gear journal diameter
Runout
Min. 35.984 mm (1.4167 in.)

Min. 27.957 mm (1.1007 in.)
Max. 0.03 mm (0.0012 in.)
Output shaft
1st gear journal diameter
2nd gear journal diameter
Runout
Min. 37.610 mm (1.4807 in.)

Min. 34.502 mm (1.3583 in.)
Max. 0.03 mm (0.0012 in.)

1st
Max.
Min.
Max.
Min.
Max.
Min.
Max.
Min.
0.40 mm (0.0157 in.)

0.25 mm (0.0098 in.)
0.35 mm (0.0138 in.)
0.10 mm (0.0039 in.)
0.57 mm (0.0224 in.)
0.10 mm (0.0039 in.)
0.65 mm (0.0256 in.)
0.10 mm (0.0039 in.)

1st, 2nd & 3rd
4th
5th
MAX.
MAX.
MAX.
0.053 mm (0.0021 in.)

0.051 mm (0.0020 in.)
0.050 mm (0.0020 in.)
No.3 shift fork to hub sleeve clearance
Max.
0.35 mm (0.014 in.)
Max.
0.69 mm (0.027 in.)
Max.
0.35 mm (0.014 in.)
Min.
Min.
Min.
Min.
0.70 mm (0.028 in.)

0.65 mm (0.026 in.)
0.75 mm (0.030 in.)
1.25 mm (0.049 in.)
2nd & 3rd

4th
5th

1st & 2nd
3rd
4th
5th
Drive in depth
Control shaft cover oil seal
Transmission case oil seal
Transaxle case oil seal
Select inner lever slotted spring pin
No.2 clutch hub
0 1.0 mm (0 0.039 in.)

3.5 0.5 mm (0.138 0.020 in.)
0 0.5 mm (0 0.020 in.)
0 0.5 mm (0 0.020 in.)
0 0.5 mm (0 0.020 in.)
0 0.5 mm (0 0.020 in.)
Mark
H
J
K
L
M
N
P
2.30 mm (0.0906 in.)

2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
http://vnx.su
SS11
No.3 clutch hub
Ball bearing
Mark
a
b
c
d
e
f
g
h
j
1
2
3
4
5
6
7
8
1.75 mm (0.0689 in.)

1.80 mm (0.0709 in.)
1.85 mm (0.0729 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0847 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
STD
0.05 0.20 mm (0.0020 0.0079 in.)

1.00 mm (0.0394 in.)
1.10 mm (0.0433 in.)
1.20 mm (0.0472 in.)
1.30 mm (0.0512 in.)
Differential case side bearing preload (at starting)
New bearing (Output shaft preload plus)
Reused bearing (Output shaft preload plus)
0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf)

0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
2.00 mm (0.0787 in.)

2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
http://vnx.su
SS12
Output shaft bearing preload (at starting)

New bearing
Reused bearing
Output shaft rear bearing adjusting shim thickness
0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf)

0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
Mark
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
1.30 mm (0.0512 in.)

1.35 mm (0.0531 in.)
1.40 mm (0.0551 in.)
1.45 mm (0.0571 in.)
1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
1.80 mm (0.0709 in.)
1.85 mm (0.0728 in.)
1.90 mm (0.0748 in.)
1.95 mm (0.0768 in.)
2.00 mm (0.0787 in.)
2.05 mm (0.0807 in.)
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
http://vnx.su
SS13

SS0G708
Part tightened
Nm
kgfcm
ftlbf
Transaxle upper side x Engine
Bolt A
Bolt B
64
25
650
296
47
21
Transaxle lower side x Engine
Bolt A
Bolt B
Bolt C
Bolt D
Bolt E
40
40
8
20
46
408
408
82
204
470
30
30
71 in.lbf
15
34
Diesel throttle body x Engine unit
21
214
15
No.1 air tube assembly x Engine unit
25
255
18
Diesel throttle body with No.2 air tube assembly x Engine unit
25
255
18
Engine front mounting x Engine front mounting bracket
87
890
64
Engine front mounting x Transaxle
64
650
47
Engine rear mounting x Engine rear mounting bracket
98
1,000
72
Engine rear mounting x Transaxle
64
650
47
Starter x Starter wire
15
153
11
Starter x Transaxle
39
400
29
Transmission case protector x Transmission
18
185
13
Clutch release cylinder x Clutch housing
12
120
12
4.9
120
50
9
43 in.lbf
Engine left mounting x Bracket
87
890
64
Engine left mounting Bracket x Transaxle
52
530
38
Front wheel
103
1,050
76
62
630
46
Front exhaust pipe x Center exhaust pipe
43
440
32
Engine rear mounting x Center member
73
740
54
Engine rear mounting bracket x Body
64
650
47
Engine rear mounting bracket x Engine rear mounting
87
890
64
Engine front mounting x Center member
52
540
38
Engine front mounting bracket x Transaxle
64
650
47
Engine front mounting bracket x Engine front mounting
87
890
64
Front transport hook x Center member
39
400
29
Engine mounting center member x Body
73
740
54
No.2 selecting bellcrank with selecting bellcrank support
20
200
14
Lock ball assembly
29
300
22
Shift and select lever shaft assembly x Transmission case
20
200
14
Transmission case cover x Transmission case
29
300
22
Clutch line bracket x Transaxle

(See page MX4)
Bolt A
Bolt B
Breather plug
49
500
36
Output shaft lock nut
123
1,250
90
Shift fork and shift head set bolt
24
240
17
Rear bearing retainer x Transmission case
42
430
31
Straight screw plug
25
250
18
Straight screw plug (Reverse restrict pin)
13
130
Reverse idler gear shaft lock bolt
29
300
22
29
300
22
http://vnx.su
SS14
Reverse shift arm bracket assembly x Transaxle case
17
175
13
Transaxle case receiver x Transaxle case
7.4
75
65 in.lbf
39
400
29
Control cable bracket x Transaxle case
17
175
13
Vehicle speed sensor
17
175
13
Clutch release line bracket x Transaxle case
17
175
13
Backup light switch
40
410
30
Filler and drain plugs
49
500
36
No.1 and No.2 oil receiver pipes x Transmission case
17
175
13
Ring gear set bolt
106
1,080
78
Shift lever assembly x Body
12
120
Retainer x Body
4.9
50
43 in.lbf
Grommet retainer x Body
4.9
50
43 in.lbf
http://vnx.su
SS15

SS09M04
SERVICE DATA
Input shaft roller bearing journal diameter
Min. 29.987 mm (1.181 in.)
Input shaft 3rd gear journal diameter
Min. 33.100 mm (1.3031 in.)
Min. 32.484 mm (1.2789 in.)
Min. 26.987 mm (1.0625 in.)
Input shaft runout
Max.
Output shaft roller bearing journal diameter
Min. 31.984 mm (1.2592 in.)
0.03 mm (0.0012 in.)
Output shaft 1st gear journal diameter
Min. 37.987 mm (1.4956 in.)
Output shaft 2nd gear journal diameter
Min. 32.002 mm (1.2599 in.)
Output shaft runout
Max.
0.05 mm (0.0020 in.)
1st
Max. 0.29 mm (0.0114 in.)

Min. 0.10 mm (0.0039 in.)
2nd
Max. 0.34 mm (0.0134 in.)

Min. 0.10 mm (0.0039 in.)
3rd
Max. 0.35 mm (0.0138 in.)

Min. 0.10 mm (0.0039 in.)
4th
Max. 0.45 mm (0.0177 in.)

Min. 0.10 mm (0.0039 in.)
5th
Max. 0.57 mm (0.0224 in.)

Min. 0.10 mm (0.0039 in.)
1st, 2nd, 3rd and 4th
Max. 0.051 mm (0.0020 in.)

Min. 0.009 mm (0.0004 in.)
5th
Max. 0.048 mm (0.0019 in.)

Min. 0.009 mm (0.0004 in.)
Shift fork to hub sleeve clearance
Max.
0.4 mm ( 0.016 in.)
Synchronizer ring to gear clearance 1st and 4th
Min. 0.75 mm (0.030 in.)
Synchronizer ring to gear clearance 2nd
Min. 0.7 mm (0.028 in.)
Synchronizer ring to gear clearance 3rd
Min. 0.65 mm (0.026 in.)
Differential case side bearing preload (at starting)(For use with SST)
1.0 1.6 Nm (10 16 kgfcm, 8.7 13.9 in.lbf)
0.05 0.20 mm (0.0020 0.0079 in.)
Drive in de
depth
th
In
Input
ut shaft front oil seal
0 0.5 mm (0 0.020 in.)
Slotted spring
g pin for reverse restrict pin
Shift and select lever shaft slotted spring pin
13.5 0.5 mm ((0.531 0.020 in.))

23.5 1.0 mm (0.925 0.039 in.)
0.95 mm (0.0374 in.)
1
1.00
00 mm (0.0394
(0 0394 in.)
in )
1
1.05
05 mm (0
(0.0413
0413 in
in.))
1 10 mm (0
1.10
(0.0433
0433 iin.))
1.15 mm ((0.0453 in.))
1.20 mm (0.0472 in.)
http://vnx.su
SS16
Input
In
ut shaft snap
sna ring thickness
No.2 clutch hub
No.3 clutch hub
Rear bearing
Mark 1
Mark 2
Mark 3
M k4
Mark
Mark 5
Mark 6
Mark 13
Mark 14
Mark 15
M k 16
Mark
Mark 17
Mark 18
Mark 19
Mark 20
Mark 21
M k 22
Mark
Mark 23
Mark 24
Mark 25
Mark 26
Mark 27
Mark A
Mark B
Mark C
Mark D
Mark E
1.95 2.00 mm (0.0768 0.0787 in.)

2.00 2.05 mm (0.0787 0.0807 in.)
2.05 2.10 mm (0.0807 0.0827 in.)
2 10 2
2.10
2.15
15 mm (0
(0.0827
0827 0
0.0846
0846 iin.))
2 15 2.20
2.15
2 20 mm (0.0846
(0 0846 0.0866
0 0866 in.)
in )
2.20 2.25 mm (0.0866 0.0886 in.)
2.20 2.25 mm (0.0866 0.0886 in.)
2.25 2.30 mm (0.0886 0.0906 in.)
2.30 2.35 mm (0.0906 0.0925 in.)
2 35 2
2.35
2.40
40 mm (0
(0.0925
0925 0
0.0945
0945 iin.))
2 40 2.45
2.40
2 45 mm (0.0945
(0 0945 0.0965
0 0965 in.)
in )
2.45 2.50 mm (0.0965 0.0984 in.)
2.50 2.55 mm (0.0984 0.01004 in.)
2.55 2.60 mm (0.1004 0.01024 in.)
2.60 2.65 mm (0.1024 0.01043 in.)
2 65 2.70
2.65
2 70 mm (0.1043
(0 1043 0.01063
0 01063 in.)
i )
2 70 2.75
2.70
2 75 mm (0
(0.1063
1063 0.01083
0 01083 in
in.))
2.75 2.80 mm (0.1083 0.01102 in.)
2.80 2.85 mm (0.1102 0.01122 in.)
2.85 2.90 mm (0.1122 0.01142 in.)
2.90 2.95 mm (0.1142 0.01161 in.)
2 15 2
2.15
2.20
20 mm (0
(0.0846
0846 0
0.0866
0866 in
in.))
2 20 2.25
2.20
2 25 mm (0.0866
(0 0866 0.0886
0 0886 in.)
in )
2.25 2.30 mm (0.0886 0.0906 in.)
2.30 2.35 mm ((0.0906 0.0925 in.))
2.35 2.40 mm (0.0925 0.0945 in.)
Mark 1
Mark 2
Mark 3
Mark 4
Mark 5
Mark 6
Mark 7
Mark 8
Mark 9
Mark 10
Mark 11
Mark 12
Mark 13
Mark 14
Mark 15
Mark 16
Mark 17
Mark 18
Mark 19
1 90 mm (0.0748
1.90
(0 0748 in.)
in )
1
1.95
95 mm (0.0768
(0 0768 in.)
in )
2
2.00
00 mm (0.0787
(0 0787 in.)
in )
2
2.05
05 mm (0.0807
(0 0807 in.)
in )
2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm ((0.0965 in.))
2.50 mm ((0.0984 in.))
2.55 mm ((0.1004 in.))
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm ((0.1102 in.))
http://vnx.su
SS17

SS09N05
Part tightened
Nm
kgfcm
ftlbf
Starter x Transaxle
39
400
29
Clutch release cylinder x Transaxle
12
120
12
4.9
120
50
9
43 in.lbf
52
530
38
Clutch line bracket x Transaxle (See page MX3)
Bolt A
Bolt B
Engine left mounting bracket x Transaxle

Engine left mounting bracket x Insulator
87
890
64
Upper bolt
64
25
650
250
47
18
Bolt A
Bolt B
43
21
440
210
32
15
Front wheel
216
2,200
159
Filler and Drain plugs
49
500
36
62
630
46
Front exhaust pipe x Center exhaust pipe
43
440
32
Front transport hook x Engine Mounting Center Member
39
400
29
73
72
740
730
54
53
Engine rear mounting bracket x Insulator
87
890
64
Engine rear mounting bracket x Transaxle
64
650
47
Intake manifold stay
44
450
33
Shift lever assembly x Body
12
120
Shift cable grommet retainer x Body
4.9
50
43 in.lbf
Transmission control cable bracket x Body
4.9
50
43 in.lbf
29
300
22
29
300
22
Transmission case protector
18
185
13
Rear bearing retainer
42
430
31
Output shaft front bearing lock plate
18
185
13
Transaxle case receiver set bolt
7.4
75
65 in.lbf
5th driven gear lock nut
123
1,250
90
No.3 shift fork x No.1 shift fork shaft
18
185
13
Reverse idler shaft lock bolt
29
300
22
Shift and select lever aseembly
37
375
27
Control shift lever x Lever shaft
6.4
65
56 in.lbf
Ring gear x Differential case
83
850
61
Selecting bellcrank x Transmission case
37
380
27
Reverse shift arm bracket
18
185
13
No.3 shift fork x Shift fork shaft
18
185
13
Lock ball assembly
29
300
22
Backup light switch
44
450
33
Differential side bearing retainer
18
185
13
Release bearing retainer
7.4
75
65 in.lbf
Straight screw plug
13
130
Transaxle x Engine (See page MX3)
Stiffener plate x Transaxle (See page MX3)
Engine Mounting Center Member (See page MX3)
Bolt A
Bolt B
http://vnx.su
SS18
Speed sensor lock plate set bolt
5.4
55
48 in.lbf
47
480
35
http://vnx.su
SS19

SS0YH02
SERVICE DATA
Line pressure (Wheel locked)
Engine idling
D range
R range
at stall (Throttle valve fully opened)
D range
R range
372 441 kPa (3.8 4.5 kgf/cm2, 54 64 psi)

598 716 kPa (6.1 7.3 kgf/cm2, 87 104 psi)
981 1,138 kPa (10.0 11.6 kgf/cm2, 142 165 psi)
1,392 1,726 kPa (14.2 17.6 kgf/cm2, 202 250 psi)
Engine stall revolution

D and R range
2,500 150 rpm
Time lag
N D range
N R range
Engine idle speed
(A/C OFF)
Drive plate runout
Torque converter runout
Torque converter correct distance
N range
Max.
Max.
Less than 1.2 seconds

700 50 rpm
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
More than 15.5 mm (0.610 in.)
Differential oil seal drive in depth

LH side
RH side
5.3 0.5 mm (0.209 0.020 in.)

3.1 0.5 mm (0.122 0.020 in.)
LHD
Shift schedule (NORM mode)
D range
(Throttle valve fully opened)
(Kickdown Switch ON)
(Throttle valve fully closed)

2 range
L range
12
23
34
43
32
21
12
23
34
43
32
21
34
43
50 58 km/h (31 36 mph)

95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
120 132 km/h (75 82 mph)
64 71 km/h (40 44 mph)
20 25 km/h (12 16 mph)
50 58 km/h (31 36 mph)
95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
42 48 km/h (26 30 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)
12
21
12
21
50 58 km/h (31 36 mph)

38 44 km/h (24 27 mph)
50 58 km/h (31 36 mph)
42 48 km/h (26 30 mph)
21
45 51 km/h (28 32 mph)
http://vnx.su
SS20
Shift schedule (PWR mode)
D range

2 range
L range
Shift schedule (SNOW mode)
D range

Lockup point (NORM mode)
3rd Gear (O/D main switch OFF)
O/D gear
Lockup point (PWR mode)

O/D gear
Lockup point (SNOW mode)

O/D gear
12
23
34
43
32
21
12
23
34
43
32
21
34
43
50 58 km/h (31 36 mph)

95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
142 155 km/h (88 96 mph)
85 93 km/h (53 58 mph)
38 44 km/h (24 27 mph)
50 58 km/h (31 36 mph)
95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
42 48 km/h (26 30 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)
12
21
12
21
50 58 km/h (31 36 mph)

38 44 km/h (24 27 mph)
50 58 km/h (31 36 mph)
42 48 km/h (26 30 mph)
21
45 51 km/h (28 32 mph)
23
34
43
32
23
34
43
32
34
43
95 103 km/h (59 64 mph)

151 164 km/h (94 102 mph)
120 132 km/h (75 82 mph)
64 71 km/h (40 44 mph)
95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)
(Throttle valve opening 5%)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
52 59 km/h (32 37 mph)

49 56 km/h (30 35 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
55 62 km/h (34 39 mph)

52 59 km/h (32 37 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
52 59 km/h (32 37 mph)

49 56 km/h (30 35 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)
http://vnx.su
SS21
RHD
D range

2 range
L range
D range

2 range
L range
D range

O/D gear

O/D gear
Lockup point (SNOW mode)
O/D gear
12
23
34
43
32
21
34
43
50 58 km/h (31 36 mph)

95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
42 48 km/h (26 30 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)
12
21
50 58 km/h (31 36 mph)

42 48 km/h (26 30 mph)
21
45 51 km/h (28 32 mph)
12
23
34
43
32
21
34
43
50 58 km/h (31 36 mph)

95 103 km/h (59 64 mph)
151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
42 48 km/h (26 30 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)
12
21
50 58 km/h (31 36 mph)

42 48 km/h (26 30 mph)
21
45 51 km/h (28 32 mph)
23
34
43
32
34
43
95 103 km/h (59 64 mph)

151 164 km/h (94 102 mph)
146 159 km/h (91 99 mph)
85 93 km/h (53 58 mph)
32 38 km/h (20 24 mph)
14 20 km/h (9 12 mph)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
52 59 km/h (32 37 mph)

49 56 km/h (30 35 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
55 62 km/h (34 39 mph)

52 59 km/h (32 37 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)

Lockup ON
Lockup OFF
Lockup ON
Lockup OFF
52 59 km/h (32 37 mph)

49 56 km/h (30 35 mph)
64 71 km/h (40 44 mph)
61 68 km/h (38 42 mph)
http://vnx.su
SS22

SS0YI02
Part tightened
Nm
kgfcm
ftlbf
Drain plug x Transaxle case
17
175
13
Oil pan set bolt
5.3
55
48 in.lbf
Oil strainer set bolt
10
100
Valve body set bolt
10
100
Detent spring
10
100
Neutral start switch x Transaxle case
5.4
55
48 in.lbf
Neutral start switch lock nut
6.9
70
61 in.lbf
Control cable x Control shift lever
12
120
Air cleaner assembly set bolt
5.0
50
43 in.lbf
87
52
890
530
64
38
Starter
39
400
29
Transaxle x Engine
64
650
47
Exhaust front pipe x Exhaust manihold
43
440
32
39
400
29
73
35
740
360
54
26
Starter connector set bolt
10
100
Control cable bracket x Transaxle
12
120
87
64
890
650
64
48
28
290
21
46
23
470
230
34
17
Ground cable x Transaxle
18
185
13
Suction hose (RHD) x Center member
35
360
26
Engine mounting bracket LH
Through bolt :
Set bolt :
Center member protector set bolt

Center member set bolt
Engine rear mounting bracket
A bolt :
B bolt :
Through bolt :
Set bolt :
Torque converter x Drive plate

Engine x Transaxle
Lower side :
A bolt :
B bolt :
http://vnx.su
SS23

SS18S02
SERVICE DATA
Line pressure (Wheel locked)
Engine idling
D range
R range
at stall (Throttle valve fully opened)
D range
R range
Engine stall revolution
Time lag
Engine idle speed

(A/C OFF)
Drive plate runout
Torque converter runout
Torque converter installation distance
Differential oil seal drive in depth
D and R range
N D range
N R range
N range
Max.
Max.
LH side
RH side
372 412 kPa (3.8 4.2 kgf/cm2, 54 59 psi)

640 742 kPa (6.5 7.6 kgf/cm2, 93 107 psi)
931 1,031 kPa (9.5 10.5 kgf/cm2, 134 149 psi)
1,768 1,968 kPa (18.0 20.1 kgf/cm2, 255 286 psi)
2,550 150 rpm
700 50 rpm
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
More than 13.4 mm (0.528 in.)
2.7 0.5 mm (0.106 0.020 in.)
0 0.5 mm (0 0.020 in.)
LHD
D range

2 range
L range
12
23
34
43
32
12
23
34
43
32
21
34
43
53 60 km/h (33 37 mph)

99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
116 128 km/h (72 80 mph)
67 74 km/h (42 46 mph)
53 60 km/h (33 37 mph)
99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
46 52 km/h (29 32 mph)
35 41 km/h (22 25 mph)
16 21 km/h (10 13 mph)
12
32
12
21
53 60 km/h (33 37 mph)

99 106 km/h (62 66 mph)
53 60 km/h (33 37 mph)
46 52 km/h (29 32 mph)
32
21
99 106 km/h (62 66 mph)

48 54 km/h (30 34 mph)
http://vnx.su
SS24
D range

2 range

L range

D range
12
23
34
43
32
21
12
23
34
43
32
21
34
43
53 60 km/h (33 37 mph)

99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
81 88 km/h (50 55 mph)
46 52 km/h (29 32 mph)
53 60 km/h (33 37 mph)
99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
46 52 km/h (29 32 mph)
35 41 km/h (22 25 mph)
17 23 km/h (11 14 mph)
12
32
21
12
21
53 60 km/h (33 37 mph)

99 106 km/h (62 66 mph)
46 52 km/h (29 32 mph)
53 60 km/h (33 37 mph)
46 52 km/h (29 32 mph)
32
21
99 106 km/h (62 66 mph)

48 54 km/h (30 34 mph)
23
34
43
32
23
34
43
32
34
43
99 107 km/h (62 66 mph)

154 166 km/h (96 103 mph)
116 128 km/h (72 80 mph)
67 74 km/h (42 46 mph)
99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
35 41 km/h (22 25 mph)
16 21 km/h (10 13 mph)

O/D gear

Lockup ON
Lockup OFF
58 64 km/h (36 40 mph)

54 60 km/h (34 37 mph)

O/D gear

Lockup ON
Lockup OFF
64 71 km/h (40 44 mph)

61 67 km/h (38 42 mph)
http://vnx.su
SS25
RHD
D range

2 range
L range
D range

2 range
L range

D range
12
23
34
43
32
21
34
43
53 60 km/h (33 37 mph)

99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
46 52 km/h (29 32 mph)
35 41 km/h (22 25 mph)
16 21 km/h (10 13 mph)
12
32
53 60 km/h (33 37 mph)

99 10 km/h (62 66 mph)
32
21
99 107 km/h (62 66 mph)

48 54 km/h (30 34 mph)
12
23
34
43
32
21
34
43
53 60 km/h (33 37 mph)

99 107 km/h (62 66 mph)
154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
46 52 km/h (29 32 mph)
35 41 km/h (22 25 mph)
17 23 km/h (11 14 mph)
12
32
53 60 km/h (33 37 mph)

99 107 km/h (62 66 mph)
32
21
99 107 km/h (62 66 mph)

48 54 km/h (30 34 mph)
23
34
43
32
34
43
99 107 km/h (62 66 mph)

154 166 km/h (96 103 mph)
146 159 km/h (91 99 mph)
92 99 km/h (57 62 mph)
35 41 km/h (22 25 mph)
16 21 km/h (10 13 mph)

O/D gear

Lockup ON
Lockup OFF
58 64 km/h (36 40 mph)

54 60 km/h (34 37 mph)

O/D gear

Lockup ON
Lockup OFF
64 71 km/h (40 44 mph)

61 67 km/h (38 42 mph)
http://vnx.su
SS26

SS0YI03
Part tightened
Nm
kgfcm
ftlbf
Input turbine speed sensor x Transaxle case
11.3
115
Counter gear speed sensor x Transaxle case
11.3
115
ATF Temperature sensor x Valve body
6.6
67
58 in.lbf
Oil strainer x Valve body
10.8
110
Oil pan x Transaxle case
7.8
80
69 in.lbf
Drain plug
49
500
36
5.4
6.9
55
70
48 in.lbf
61 in.lbf
Shaft lever x Body
12
120
Shift control cable x Control shaft lever
13
130
6.6
10.8
67
110
58 in.lbf
8
Valve body x Transaxle case
10.8
110
Air cleaner assembly set bolt
5.0
50
43 in.lbf
87
52
890
530
64
38
39
400
29
64
650
47
Exhaust front pipe x Exhaust manihold
62
630
46
Center member protector set bolt
39
400
29
73
35
740
360
54
26
Starter connector set bolt
10
100
Control cable bracket x Transaxle
12
120
87
64
890
650
64
48
41
420
30
Lower side :
46
470
34
A bolt :
B bolt :
6.6
11
67
110
58 in.lbf
8
Ground cable x Transaxle
18
185
13
Suction hose (RHD) x Center member
35
360
26
Neutral start switch x Transaxle
Solenoid valve x Valve body

(See page AX8)
Engine mounting bracket LH
Bolt:
Nut:
Bolt A:
Bolt B:
Through bolt :
Set bolt :
Starter
Transaxle x Engine
Center member set bolt
Engine rear mounting bracket
Upper side :
A bolt :
B bolt :
Through bolt :
Set bolt :
Torque converter x Drive plate

Engine x Transaxle
Solenoid valve x Valve body
http://vnx.su
SS27
SUSPENSION AND AXLE
SUSPENSION AND AXLE

SS0IY03
SERVICE DATA
Drive shaft standard length
1ZZFE engine (M/T)
RH
LH
943.60 1.0 mm (37.15 0.039 in.)

657.90 0.8 mm (25.90 0.032 in.)
1ZZFE engine (A/T)
RH
LH
943.60 1.0 mm (37.15 0.039 in.)

653.20 0.8 mm (25.72 0..032 in.)
3ZZFE engine
RH
LH
944.70 0.8 mm (37.19 0.032 in.)

655.70 0.8 mm (25.82 0.032 in.)
1AZFSE engine
RH
LH
922.65 1.0 mm (36.32 0.039 in.)

650.85 0.7 mm (25.62 0.028 in.)
Front drive shaft
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SS28
SUSPENSION AND AXLE

SS0IZ03
Part tightened
Nm
kgfcm
ftlbf
Steering knuckle x Shock absorber
255
2,600
188
Suspension support x Body
80
820
59
Suspension support x Piston rod
47
475
34
ABS speed sensor set bolt
8.0
82
71 in.lbf
ABS speed sensor wire harness clamp x Shock absorber
5.5
55
48 in.lbf
Flexible hose x Shock absorber bracket
29
300
22
FRONT:
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SS29
BRAKE
BRAKE
SS0FS06
SERVICE DATA
Brake pedal height (from asphalt sheet)
LHD
RHD
147.0 157.0 mm (5.787 6.181 in.)

149.5 159.5 mm (5.886 6.280 in.)
Brake pedal freeplay
1 6 mm (0.04 0.24 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf)

LHD Gasoline engine (w/o ABS)
LHD Others
RHD Gasoline engine (w/o ABS)
RHD Others

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SS30
STEERING
STEERING
SS0IF03
SERVICE DATA
Oil level rise
Maximum 5 mm (0.20 in.)

Minimum 8,300 kPa (85 kgf/cm2, 1,209 psi)
Oil pressure at idle speed with valve closed

1AZFSE Engine:
Minimum 8,800 kPa (90 kgf/cm2, 1,280 psi)
Oil pressure at idle speed with valve closed

Vane pump rotating torque
Vane pump shaft and front housing bushing oil clearance
STD 0.021 0.043 mm (0.0008 0.0017 in.)

Maximum 0.07 mm (0.0028 in.)
Vane plate height
Minimum 7.6 mm (0.299 in.)
Vane plate thickness
Minimum 1.405 mm (0.0553 in.)
Vane plate length
Minimum 11.993 mm (0.4722 in.)
Vane plate and vane pump rotor groove clearance
Maximum 0.03 mm (0.0012 in.)
Vane plate length
pump rotor and cam ring mark
Spring free length
12.001 12.003 mm (0.47248 0.47256 in.)
11.999 12.001 mm (0.47240 0.47248 in.)
11.997 11.999 mm (0.47232 0.47240 in.)
11.995 11.997 mm (0.47224 0.47232 in.)
11.993 11.995 mm (0.47216 0.47224 in.)

Vane pump rotating torque
Vane pump shaft and front housing bushing oil clearance
STD 0.021 0.043 mm (0.0008 0.0017 in.)

Maximum 0.07 mm (0.0028 in.)
Vane plate height
Vane plate thickness
Minimum 1.405 mm (0.0553 in.)
Vane plate length
Minimum 11.993 mm (0.4722 in.)
Vane plate and vane pump rotor groove clearance

Vane plate length
Spring free length
Maximum 0.03 mm (0.0012 in.)
pump rotor and cam ring mark

0
12.001 12.003 mm (0.47248 0.47256 in.)
11.999 12.001 mm (0.47240 0.47248 in.)
11.997 11.999 mm (0.47232 0.47240 in.)
11.995 11.997 mm (0.47224 0.47232 in.)
11.993 11.995 mm (0.47216 0.47224 in.)
*: For use with belt tension gauge
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SS31
STEERING
SS0IG03
Part tightened
Nm
kgfcm
ftlbf
25.5
260
19
35
360
26
Steering wheel set nut
50
510
37
Steering wheel pad set screw (Torx screw)
8.8
90
78 in.lbf
Rear housing set bolt
22
220
16
Pressure port union x Front housing
69
700
51
Suction port union set bolt
12
120
Oil pressure switch
21
210
15
PS vane pump assembly set nut
37
370
27
37(44)
375(450)
27(33)
7.8
80
69 in.lbf
Rear housing set bolt
22
220
16
Pressure port union x Front housing
69
700
51
Suction port union set bolt
12
120
Oil pressure switch
21
210
15
PS vane pump assembly set bolt
50
510
37
Pressure feed tube x PS vane pump assembly
52
530
38

Steering column assembly set bolt and nut
Control valve shaft x Yoke
Pressure feed tube x PS vane pump assembly

Pressure feed tube x Rear bracket
( ): For use without SST
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SS32
BODY
BODY
SS0BN02
Part tightened
Nm
kgfcm
ftlbf
20
205
15
FRONT BUMPER
Bumper reinforcement x Body
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SS33
AIR CONDITIONING
AIR CONDITIONING
SS03806
SERVICE DATA
Refrigerant volume
460 20 g (16.23 0.71 oz.)
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SS34
AIR CONDITIONING
SS05007
Part tightened
Nm
kgfcm
ftlbf
Compressor x Compressor bracket
25
250
18
Compressor x Discharge hose
10
100
Compressor x Suction hose
10
100
Condenser x Liquid tube
5.5
55
48 in.lbf
Condenser x Discharge hose
5.5
55
48 in.lbf
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DIAGNOSTICS
DI1
HOW TO PROCEED WITH
DIAGNOSTIC TROUBLE CODE CHART . . . . . .
DI132
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .
DI133
DI1
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .
DI134
CUSTOMER PROBLEM ANALYSIS CHECK . . .
DI2
PROBLEM SYMPTOMS TABLE . . . . . . . . . . . . .
DI135
PRECHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI3
CIRCUIT INSPECTION . . . . . . . . . . . . . . . . . . . . .
DI136
DI15
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .
DI16
ABS WITH EBD & BA & TRC & VSC

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI169
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .
DI17
DI18
DI23
DI170
DI60
PRECHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI171
HOW TO PROCEED WITH
HOW TO PROCEED WITH

DI169
DI176
DI60
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .
DI178
DI61
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .
DI179
PRECHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI62
DI181
DI74
DI182
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .
DI76
ENGINE IMMOBILISER SYSTEM . . . . . . . . . .
DI255
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .
DI77
DI79
DI82
DI256
PRECHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI257
DI259
PARTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .
DI260
ANTILOCK BRAKE SYSTEM WITH

ELECTRONIC BRAKE FORCE
DISTRIBUTION (EBD) . . . . . . . . . . . . . . . . . .
DI127
HOW TO PROCEED WITH
HOW TO PROCEED WITH

DI255
TERMINALS OF ECU . . . . . . . . . . . . . . . . . . . . . .
DI261
DI263
DI264
DI127
DI128
PRECHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DI129

Manual Name
Pub. No.
RM599E

RM698E
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DI1
DIAGNOSTICS

DI2L410

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
Customer Problem Analysis

P. DI2
Connect the handheld tester to DLC3.

If the display shows UNABLE TO CONNECT TO VEHICLE when you have connected the
handheld tester, inspect DLC3 P. DI3
Check DTC and Freeze Frame Data (Precheck)

Record or Print DTC and Freeze Frame Data P DI3
Clear DTC and Freeze Frame Data P. DI15
5 Visual Inspection
6
Setting the Check Mode Diagnosis P. DI3
Symptom does not occur

7
Problem Symptom Confirmation
Symptom Simulation
P. IN20
Symptom occurs
9
10
DTC Check
P. DI3
OK Code 11
Basic Inspection NG
P. DI3
OK
12
DTC Chart
P. DI15
OK 13
14
Manual Shifting Test

P. DI3
Chapter 2
(OnVehicle)
P. DI18
OK
NG
Circuit
Inspection
OK
NG
Problem Symptoms Table P. DI18

Chapter 1
(Electronic)
P. DI18
15
NG
Mechanical System Test

P. DI3
OK
NG
Chapter 3
(OffVehicle)
P. DI18
NG
S O/D Main Switch & O/D OFF Indicator Light Check

S Kickdown Switch Circuit Check
16
Parts Inspection
P. DI23 to DI57
17
Identification of Problem
18
Repair
Confirmation Test
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End
DI2
DIAGNOSTICS

DI2L504
Transaxle Control
System Check Sheet
Inspectors
Name
Registration No.
Customers Name
Registration Year
Frame No.
Date Vehicle
Brought In
Date Problem
Occurred
How Often Does
Problem Occur?
km
mile
Odometer Reading
/
j Continuous
/
j Intermittent (
j Vehicle does not move ( j Any range

j No upshift
( j 1st 2nd
j No downshift
( j O/D 3rd
times a day)
j Particular range )
j 2nd 3rd
j 3rd 2nd
j 3rd O/D )
j 2nd 1st )
j Lockup malfunction
Symptoms
j Shift point too high or too low

j Harsh engagement ( j N D
j Lockup
j Any drive range )
j Slip or shudder
j No kickdown
j Others
Check Item
Malfunction
Indicator Light
j Normal
j Remains ON
1st Time
j Normal code
j Malfunction code (Code
2nd Time
j Normal code
j Malfunction code (Code
DTC Check
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DI3
DIAGNOSTICS

DI80A01
PRECHECK
1.
(a)
DIAGNOSIS SYSTEM
Description
S
When troubleshooting EuroOBD vehicles, the
only difference from the usual troubleshooting procedure is that you connect an OBD scan tool complying with ISO150314 or handheld tester to the
vehicle, and read off various data output from the
vehicles engine and ECT ECU.
S
EuroOBD regulations require that the vehicles

onboard computer lights up the check engine
warning light (CHK ENG) on the instrument panel
when the computer detects a malfunction in the
computer itself or in drive system components
which affect vehicle emissions. In addition to the
CHK ENG lighting up when a malfunction is detected, the applicable DTCs prescribed by
ISO150316 are recorded in the engine and ECT
ECU memory (See page DI15).
If the malfunction only occurs in 3 trips, the CHK
ENG goes off but the DTCs remain recorded in the
engine and ECT ECU memory.
To check the DTCs, connect an OBD scan tool or

handheld tester to the Data Link Connector
(DLC3) on the vehicle. The OBD scan tool or hand
held tester also enables you to erase the DTCs and
check freeze frame data and various forms of engine data (For instruction book).
DTCs include ISO controlled codes and manufacturer controlled codes.
ISO controlled codes must be set as prescribed by
the ISO, while manufacturer controlled codes can
be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI15).
A13822
Handheld Tester
DLC3
D01600
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DI4
DIAGNOSTICS
(b)
The diagnosis system operates in normal mode

during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use
2 trip detection logic(*) to prevent erroneous detection. By switching the engine and ECT ECU to
check mode when troubleshooting, the technician
can cause the CHK ENG to light up and for a malfunction that is only detected once or momentarily.
(handheld tester) (See page DI3)
*2 trip detection logic:
When a logic malfunction is first detected, the malfunction is temporarily stored in the engine and ECT
ECU memory. If the same malfunction is detected
again during the 2nd test drive, this 2nd detection
causes the CHK ENG to light up .
Inspect the DLC3.

The vehicles engine and ECT ECU uses ISO 91412 for
communication. The terminal arrangement of DLC3 complies with ISO150313 and matches the ISO 91412 format.
1 2 3 4 5 6 7 8
9 10111213141516
DLC3
A04550
Tester connection
7 (Bus Line) 5 (Signal ground)
Condition
During communication
Specified condition
Pulse generation
4 (Chassis Ground) Body
Always
1 or less
16 (B+) Body
Always
9 14 V
HINT:
If your display shows UNABLE TO CONNECT TO VEHICLE
when you have connected the cable of OBD scan tool or hand
held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool
side.
S
If communication is normal when the tool is connected to
another vehicle, inspect the DLC3 on the original vehicle.
S
If communication is still not possible when the tool is connected connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department
listed in the tools instruction manual.
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DI5
DIAGNOSTICS
2.
(a)
A13822
Handheld Tester
DLC3
D01600
INSPECT DIAGNOSIS (Normal Mode)

Check the CHK ENG.
(1) The CHK ENG comes on when the ignition switch
is turned ON and the engine is not running.
HINT:
If the CHK ENG does not light up, troubleshoot the combination
meter (See page BE1).
(2) When the engine is started, the CHK ENG should
go off. If the lamp remains on, the diagnosis system
has detected a malfunction or abnormality in the
system.
(b) Check the DTC.

NOTICE:
Handheld tester only: When the diagnostic system is
switched from the normal mode to the check mode, it
erases all DTCs and freeze frame data recorded in normal
mode. So before switching modes, always check the DTCs
and freeze frame data, and note them down.
(1) Prepare an OBD scan tool or handheld tester.
(2) Connect the OBD scan tool or handheld tester to
the DLC3 at the lower of the instrument panel.
(3) Turn the ignition switch ON and push the OBD scan
tool or handheld tester switch ON.
(4) Use the OBD scan tool or handheld tester to check
the DTCs and freeze frame data and note them
down (For operating instructions, see the OBD scan
tools instruction book).
(5) See page DI15 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD scan tool (excluding handheld tester) to check the DTCs, use normal
mode. For codes on the DTCs chart subject to 2 trip detection logic, turn the ignition switch OFF after the symptom
is simulated the 1st time. Then repeat the simulation process again. When the problem has been simulated twice,
the CHK ENG is indicated on the instrument panel and
DTCs are recorded in the engine and ECT ECU.
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DI6
DIAGNOSTICS
3.
INSPECT DIAGNOSIS (Check Mode)
HINT:
Handheld tester only: Compared to the normal mode, the
check mode has high sensing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
Normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Check the initial conditions.
S
Battery positive voltage 11 V or more.
S
Throttle valve fully closed.
S
Transaxle in P position.
S
A/C switched off.
(2) Turn the ignition switch OFF.
(3) Prepare the handheld tester.
Handheld Tester
(4)
(5)
Connect the handheld tester to DLC3 at the lower

of the instrument panel.
Turn the ignition switch ON and switch the hand
held tester ON.
DLC3
D01600
(6)
0.13 sec.
(7)
0.13 sec.
ON
(8)
OFF
BR3904
Switch the handheld tester from normal mode to

check mode (Check that the CHK ENG flashes).
Start the engine (CHK ENG goes out after the engine starts).
Simulate the conditions of the malfunction described by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
handheld tester diagnosis selector to check the
DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF, as turning it off
switches the diagnosis system from check mode to normal
mode, so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable circuit.
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DI7
DIAGNOSTICS
(b)
Clear the DTC.

The following actions will erase the DTC and freezed
frame data. Operating an OBD scan tool or handheld
tester to erase the codes (See the OBD scan tools
instruction book for operating instructions.).
4.
PROBLEM SYMPTOM CONFIRMATION
Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the
trouble. If the problem is that the transaxle does not shift up, shift down, or the shift point is too high or too
low conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms.
5.
ROAD TEST
NOTICE:
Conduct the test at normal operating ATF temperature 50 80 C (122 176 F).
(a) D range test
Shift into the D range and fully depress the accelerator pedal and check the following points:
(1) Check upshift operation.
Check to see that 1 2, 2 3 and 3 O/D upshift takes place, and that the shift points conform to the automatic shift schedule (See page SS19).
HINT:
S
O/D Gear Upshift Prohibition Control (1. Water temp. is 60 C (140 F) or less. 2. If there is a 10 km/h
(6 mph) difference between the set cruise control speed and vehicle speed.)
S
O/D Gear Lockup Prohibition Control (1. Brake pedal is depressed. 2. Water temp. is 60 C (140 F)
or lower)
(2) Check for shift shock and slip.
Check for shock and slip at the 1 2, 2 3 and 3 O/D upshift.
(3) Check for abnormal noises and vibration.
Run in D range lockup or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
sure to loss of balance in the differential, torque converter, etc.
(4) Check kickdown operation.
While running in the D range, 2nd, 3rd and O/D gears, check to see that the possible kickdown
vehicle speed limits for 2 1, 3 2 and O/D 3 kickdowns conform to those indicated in the
automatic shift schedule (See page SS19).
(5) Check for abnormal shock and slip at kickdown.
(6) Check the lockup mechanism.
S
Drive in D range O/D gear, at a steady speed (lockup ON) of about 60 km/h (37 mph).
S
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lockup.
(b) 2 range test
Shift into the 2 range and fully depress the accelerator pedal and check the following points:
Check to see that the 1 2 upshift takes place and that the shift point conforms to the automatic
shift schedule (See page SS19).
HINT:
There is no O/D upshift and lockup in the 2 range.
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DI8
DIAGNOSTICS
(2)
Check engine braking.

While running in the 2 range and 2nd gear, release the accelerator pedal and check the engine
braking effect.
(3) Check for abnormal noises during acceleration and deceleration, and for shock at upshift and
downshift.
(c) L range test
Shift into the L range and fully depress the accelerator pedal and check the following points:
(1) Check no upshift.
While running in the L range, check that there is no upshift to 2nd gear.
(2) Check engine braking.
While running in the L range, release the accelerator pedal and check the engine braking effect.
(3) Check for abnormal noises during acceleration and deceleration.
(d) R range test
Shift into the R range and fully depress the accelerator pedal and check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from people and obstruction.
(e) P range test
Stop the vehicle on a grade (more than 5) and after shifting into the P range, release the parking
brake. Then, check to see that the parking lock pawl holds the vehicle in place.
6.
BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 80 C (158 176 F)
(1)
(2)
(3)
(4)
Park the vehicle on a level surface and set the parking brake.
With the engine idling and the brake pedal depressed, shift the shift lever into all ranges from P
to L range and return to P range.
Pull out the dipstick and wipe it clean.
Push it back fully into the pipe.
D01529
(5)
Pull it out and check that the fluid level is in the HOT
range.
If the level is not within the range, add new fluid.
Fluid type: ATF Type DII or DEXRONIII (DEXRONII)
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
OK if hot
Add if hot
AT3417
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DI9
DIAGNOSTICS
(c)
Replace the ATF.

(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
F00483
(3)
With the engine OFF add new fluid through the oil
filler pipe.
Fluid type: ATF Type DII or DEXRONIII (DEXRONII)
Capacity: 3.1 liters (3.3 US qts, 2.7 Imp.qts)
(4) Start the engine and shift the shift lever into all
ranges from P to L range and then shift into P range.
Z13623
(5)
OK if hot
(6)
Add if hot
AT3417
With the engine idling, check the fluid level. Add

fluid up to the COOL level on the dipstick.
Check the fluid level at the normal operating temperature, 70 80 C (158 176 F), and add as
necessary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to repair or replace Orings,
FIPGs, oil seals, plugs or other parts.
(e)
Q08545
Inspect and adjust the shift lever range.

When shifting the shift lever from the N range to the other
range, check that the lever can be shifted smoothly and
accurately to each range and that the range indicator correctly indicates the range.
If the indicator is not aligned with the correct range, carry out the
following adjustment procedures:
(1) Loosen the nut the control shaft lever.
(2) Push the control shaft lever fully downward.
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DI10
DIAGNOSTICS
(3)
Return the control shaft lever 2 notches to the N

range.
(4) Set the shift lever to N range.
(5) While holding the shift lever lightly toward the R
range side, tighten the shift lever nut.
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D range and reveres when shifting it to the R range.
Q02281
(f)
Neutral
Basic Line
Groove
Q02284
Inspect and adjustment the neutral start switch.

Check that the engine can be started with the shift lever
only in the N or P range, but not in other ranges.
If not as started above, carry out the following adjustment procedures:
(1) Loosen the neutral start switch bolt and set the shift
lever to the N range.
(2) Align the groove and the neutral basic line.
(3) Holding the shift selector, and tighten the bolt.
HINT:
For continuity inspection of the neutral start switch, see page
DI45.
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DI11
DIAGNOSTICS
7.
(a)
MECHANICAL SYSTEM TESTS

Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
NOTICE:
S
Do the test at normal operating ATF temperature 50 80 C (122 176 F).
S
Do not continuously run this test for longer than 5 seconds.
S
To ensure safety, do this test in a wide, clear level area which provides good traction.
S
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(1) Chock the 4 wheels.
(2) Connect a handheld tester to DLC3.
(3) Fully apply the parking brake.
(4) Keep your left foot pressing firmly on the brake pedal.
(5) Start the engine.
(6) Shift into the D range. Press all the way down on the accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
Stall speed: 2,500 150 rpm
(8) Do the same test in the R range.
Evaluation:
Problem
Possible cause
(a) Stall speed low in D and R ranges
S Engine output may be insufficient

S Stator oneway clutch not operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D range
S Line pressure too low

S Forward clutch slipping
S Oneway clutch No.2 not operating properly
S U/D oneway clutch not operating properly
(c) Stall speed high in R range

S Reverse clutch slipping
S 1st and reverse brake slipping
S U/D brake slipping
(d) Stall speed high in D and R ranges

S Improper fluid level
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DI12
DIAGNOSTICS
(b)
Measure the time lag.

When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
and 1st and reverse brake.
NOTICE:
S
S
Be sure to allow 1 minute interval between tests.
S
Take 3 measurements and take the average value.
(3) Start engine and check idle speed.
Idle speed: 700 50 rpm (In N range and A/C OFF)
(4) Shift the lever from N to D range. Using a stop watch, measure the time from when the lever is
shifted until the shock is felt.
Time lag: N D less than 1.2 seconds
(5) In the same way, measure the time lag for N R.
Time lag: N R less than 1.5 seconds
Evaluation (If N D or N R time lag is longer than the specified):
Problem
Possible cause
N D time lag is longer

S Forward clutch worn
N R time lag is longer

S Direct clutch worn
S 1st and reverse brake worn
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DI13
DIAGNOSTICS
8.
HYDRAULIC TEST
Measure the line pressure.
NOTICE:
S
Do the test at normal operation ATF temperature 50 80 C (122 176 F).
S
The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.
S
Be careful to prevent SSTs hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the test plug on the rear side of the transaxle case and connect SST (See page AX28
for the location to connect SST).
SST 0999200095 (09992 00231, 0999200271)
(3) Fully apply the parking brake and chock the 4 wheels.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressing firmly on the brake pedal and shift into D range.
(7) Measure the line pressure when the engine is idling.
(8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when
engine speed reaches stall speed.
(9) In the same way, do the test in R range.
Specified line pressure:
Condition
D range
kPa (kgf / cm2, psi)
R range
Idling
372 441 (3.8 4.5, 54 64)
598 716 (6.1 7.3, 87 104)
Stall
981 1,138 (10.0 11.6, 142 165)
1,392 1,726 (14.2 17.6, 202 250)
Evaluation:
Problem
Possible cause
If the measured values at all ranges are higher
S SLT solenoid valve defective

S Regulator valve detective
If the measured values at all ranges are lower
S SLT solenoid valve defective

S Regulator valve defective
S Oil pump defective
S O/D direct clutch defective
If pressure is low in the D range only
S D range circuit fluid leakage

S Forward clutch defective
If pressure is low in the R range only
S R range circuit fluid leakage

S Direct clutch defective
S 1st and reverse brake defective
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DI14
DIAGNOSTICS
Q02283
9.
MANUAL SHIFTING TEST
HINT:
By this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transaxle.
(a) Disconnect the solenoid wire.
(b) Inspect the manual driving operation.
Check that the shift and gear positions correspond to the
table below.
While driving, shift through the L, 2 and D ranges.
Check that the gear change corresponds to the shift
range.
Shift range
Gear position
O/D
3rd
1st
Reverse
Pawl Lock
HINT:
If the L, 2 and D range gear positions are difficult to distinguish,
do the above read test.
If any abnormality is found in the above test, the problem is in
the transaxle itself.
(c) Connect the solenoid wire.
(d) Cancel out the DTC.
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DI15
DIAGNOSTICS

DI1FQ05

If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given.
DTC No.
(See Page)
Detection Item
Trouble Area
Check engine
warning light *1
Memory *2
Vehicle speed sensor

malfunction
S Open or short in vehicle speed sensor circuit

S Vehicle speed sensor
S Combination meter
S Engine and ECT ECU
S Automatic transaxle (clutch, brake or gear etc.)
Shift solenoid A malfunction

(No. 1 solenoid valve)
S No. 1 solenoid valve is stuck open or closed

S Valve body is blocked up or stuck
Shift solenoid A electrical

malfunction
S Open or short in No. 1 solenoid valve circuit

S No. 1 solenoid valve
Shift solenoid B malfunction

S No.2 solenoid valve is stuck open or closed

Shift solenoid B electrical

malfunction
S Open or short in No.2 solenoid valve circuit

S No.2 solenoid valve
Shift solenoid E malfunction

(SL solenoid valve)
S SL solenoid valve is stuck open or closed

S Lockup clutch
P0773
(DI34)
Shift solenoid E electrical

malfunction
(SL solenoid valve)
S Open or short in SL solenoid valve circuit

S SL solenoid valve
P1520
(DI37)
Stop light switch

signal malfunction
S Open or short in stop light switch signal circuit

S Stop light switch
P1760
(DI42)
Linear solenoid line

pressure control circuit
malfunction
(SLT solenoid valve)
S Open or short in SLT solenoid valve circuit

S SLT solenoid valve
S Engine and ECU ECU
P1780
(DI45)
Neutral start switch

malfunction
S Short in neutral start switch circuit

S Neutral start switch
P0500
(DI23)
P0750 *3
(DI26)
P0753
(DI28)
P0755 *3
(DI26)
P0758
(DI28)
P0770 *3
(DI32)
*1: f mark means Check engine warning light blinks once every 2 seconds.
X mark means Check engine warning light never blinks.
*2: f mark means Engine and ECT ECU memorizes the malfunction code if the Engine and ECT ECU
detects the DTC detection condition.
*3: European spec. only
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DI16
DIAGNOSTICS
PARTS LOCATION
DI1FR05
No. 1 Solenoid Valve

Neutral Start Switch
SL Solenoid Valve
SLT Solenoid Valve
O/D OFF Indicator

LHD:
Kickdown Switch
DLC3
Stop Light Switch
O/D Main Switch

Engine and ECT ECU
D09911
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DI17
DIAGNOSTICS

DI77O02
TERMINALS OF ECU
Engine and ECT ECU Terminals
E18
E19
E20
E21
9 8 7 6 5 4 3
2 1
2120 1918 17 16 15 1413 12 11 10
31 30 29 28 27 2625 24 23 22
7 6 5 4 3
2 1
16 1514 13 12 11 10 9 8
24 23 22 2120 1918 17
9 8 7
6 5 4 3 2 1
1918 17 16 1514 13 12 11 10
28 27 2625 24 23 22 2120
7 6
5 4 3 2 1
1514 13 12 11 10 9 8
22 21 20 1918 17 16
D05962
Symbols (Terminals No.)
Wiring Color
LG BR
S1 (E188)
(
) E1 ((E1917))
S2 (E1820)
(
) E1 ((E1917))
VW BR
P BR
SL (E1819)
(E18 19) E1 (E19
(E1917)
17)
L BR
OD2 (E2019)
(E20 19) E1 (E1917)
(E19 17)
L (E2012)
(E20 12) E1 (E1917)
(E19 17)
Y G BR
YG
O BR
2 (E203)
(E20 3) E1 (E19
(E1917)
17)
R (E202)
(E20 2) E1 (E1917)
(E19 17)
NSW (E2013)
(E20 13) E1 (E19
(E1917)
17)
R B BR
RB
B W BR
BW
SLT+ (E186) SLT (E185)
LGB PB
SPD (E2022) E1 (E1917)
G BR
KD (E204)
(E20 4) E1 (E19
(E1917)
17)
Y BR
STP (E206)
(E20 6) E1 (E19
(E1917)
17)
G W BR
GW
P BR
PWR (E2028)
(E20 28) E1 (E19
(E1917)
17)
SNWI (E2016)
(E20 16) E1 (E1917)
(E19 17)
P B BR
PB
Condition
STD Voltage (V)
IG ON
9 14
1st or 2nd gear
94
3rd or O/D gear
Below 1.5
IG ON
Below 1.5
2nd or 3rd gear
94
1st or O/D gear
Below 1.5
IG ON
Below 1.5
Vehicle driving under lockup position
9 14
O/D main switch ON (O/D OFF)
Below 3
O/D main switch OFF (O/D ON)
9 14
IG ON and Shift lever L range

IG ON and Shift lever other than L range
IG ON and Shift lever 2 range
IG ON and Shift lever other than 2 range
IG ON and Shift lever R range
IG ON and Shift lever other than R range
IG ON and Shift lever P or N range
7.5 14
Below 1.5
7.5 14
Below 1.5
7.5 14
Below 1.5
Below 3
IG ON and Shift lever other than P or N range
9 14
IG ON
9 14
IG ON and rotate driving wheel slowly

IG ON and accelerator pedal fully depressed
Pulse generation
Below 1.5
IG ON and accelerator pedal released
9 14
IG ON and brake pedal depressed
9 14
IG ON and brake pedal released

IG ON and pattern select switch: PWR
IG ON and pattern select switch: NORM
Below 1.5
9 14
Below 1.5
IG ON and SNOW mode switch: ON
9 14
IG ON and SNOW mode switch: OFF
Below 1.5
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DI18
DIAGNOSTICS

DI1FT06

If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
HINT:
The Matrix Chart is divided tnto 3 chapters.
Chapter 1: Electronic circuit matrix chart
Chapter 2: Onvehicle repair matrix chart
Chapter 3: Offvehicle repair matrix chart
If the instruction Proceed to next circuit inspection shown on matrix chart is given in the flow chart for eaxh
circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and
replace the Engine and ECT ECU.
Symptom
Suspect Area
See page
No upshift
(A particular gear, from 1st to 3rd gear, is not upshifted)
Engine and ECT ECU
IN30
No upshift
(3rd O/D)
1. O/D main switch & O/D OFF indicator light circuit

2. Engine and ECT ECU
DI49
IN30
No downshift
(O/D 3rd)

DI49
IN30
No downshift
(A particular gear, from 1st to 3rd gear, is not downshifted)
Engine and ECT ECU
IN30
No lockup
Engine and ECT ECU
IN30
No lockup OFF
Engine and ECT ECU
IN30
Shift point too high or too low
Engine and ECT ECU
IN30
Upshift to O/D from 3rd while O/D main switch is OFF

DI49
IN30
Upshift to O/D from 3rd while engine is cold
Engine and ECT ECU
IN30
No kickdown
1. Kickdown switch circuit

DI57
IN30
Engine stalls when starting off or stopping
Engine and ECT ECU
IN30
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DI19
DIAGNOSTICS
Chapter 2: Onvehicle repair

(L : A245E automatic transaxle repair manual Pub. No. RM757E)
Symptom
Suspect Area
See page
Does not move in any forward ranges
Offvehicle matrix chart
Does not move in reverse range
Does not move in any range
1. Primary regulator valve

2. Manual valve
3. Offvehicle matrix chart
L
L
Noup shift
(1st 2nd)
1. 1 2 shift valve
Noup shift
(2nd 3rd)
1. 2 3 shift valve
Noup shift
(3rd O/D)
1. 3 4 shift valve
Nodown shift
(O/D 3rd)
1. 3 4 shift valve
Nodown shift
(3rd 2nd)
1. 2 3 shift valve
Nodown shift
(2nd 1st)
1. 1 2 shift valve
Harsh engagement
(N R)
1. C2 accumulator
Harsh engagement
(N D)
1. C1 accumulator
Harsh engagement
(N L)
1. C1 accumulator
2. Low coast modulator valve
L
L
Harsh engagement
(1st 2nd D range)
1. Accumulator control valve

2. B2 accumulator
L
L
Harsh engagement
(1st 2nd 2 range)
1.
2.
3.
4.
L
L
L
Harsh engagement
(1st 2nd 3rd O/D)
Primary regulator valve
Harsh engagement
(2nd 3rd)
1. C2 accumulator
2. Accumulator control valve
L
L
Harsh engagement
(3rd O/D)
1. B2 accumulator
2. C3 accumulator
L
L
Harsh engagement
(O/D 3rd)
1. B4 accumulator
Harsh engagement
(3rd 2nd)
1. C2 accumulator
Slip (Forward & Reverse)

2. Oil strainer
L
AX4
Slip (R range, 1st, 2nd, 3rd, O/D)
B2 accumulator
Accumulator control valve
2nd coast modulator control
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DI20
DIAGNOSTICS
Symptom
Suspect Area
See page
No engine braking (1st L range)
1. Low coast modulator valve

No engine braking (2nd 2 range)
1. 2nd coast modulator valve

No kick down
1. 1 2 shift valve
2. 2 3 shift valve
3. 3 4 shift valve
L
L
L
Poor acceleration

No lockup
1. Lockup relay valve

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DI21
DIAGNOSTICS
Chapter 3: Offvehicle repair

(L : A245E automatic transaxle repair manual Pub. No. RM757E)
Symptom
Suspect Area
See page
Does not move in any forward ranges
Forward clutch (C1)
Does not move in reverse range
1. Direct clutch (C2)

2. 1st and reverse brake (B3)
3. U/D brake (B4)
L
L
L
Does not move in any ranges
1.
2.
3.
4.
5.
Noup shift
(1st 2nd)
1. 2nd brake (B2)

2. No.1 oneway clutch (F1)
L
L
Noup shift
(2nd 3rd)
Direct clutch (C2)
Noup shift
(3rd O/D)
U/D clutch (C3)
Nodown shift
(O/D 3rd)
1. U/D brake (B4)

2. U/D oneway clutch (F3)
L
L
Nodown shift
(3rd 2nd)
No.1 oneway clutch (F1)
Nodown shift
(2nd 1st)
Harsh engagement
(N R)

L
L
Harsh engagement
(N D)
1. Forward clutch (C1)

2. Onvehicle matrix chart
Harsh engagement
(N L)
Forward clutch (C1)
Harsh engagement
(1st 2nd D range)
1. 2nd brake (B2)

L
L
Harsh engagement
(1st 2nd 2 range)
1. 2nd coast brake (B1)

2. 2nd brake (B2)
L
L
L
Harsh engagement
(2nd 3rd)
Direct clutch (C2)
Harsh engagement
(3rd O/D)
U/D clutch (C3)
Harsh engagement
(O/D 3rd)
U/D brake (B4)
Harsh engagement
(3rd 2nd)
Direct clutch (C2)
Slip (Forward & Reverse)
1. Torque converter
2. Oil pump
Slip (R range)

L
L
Slip (1st)

L
L
L
Torque converter
Oil pump
U/D oneway clutch (F3)
Front planetary gear
Rear planetary gear
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AX33
L
L
L
L
AX33
L
DI22
DIAGNOSTICS
Symptom
Suspect Area
Forward clutch (C1)
2nd brake (B2)
See page
L
L
L
L
Slip (2nd)
1.
2.
3.
4.
Slip (3rd)

L
L
L
Slip (O/D)

3. U/D clutch (C3)
L
L
L
No engine braking (1st L range)
1st and reverse brake (B3)
No engine braking (2nd 2 range)
2nd coast brake (B1)
Poor acceleration
1. Torque converter
AX33
L
No lockup
Torque converter
AX33
Torque converter
AX33
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DI23
DIAGNOSTICS

DI3VC05
CIRCUIT INSPECTION
DTC
P0500
Speed Sensor Malfunction
The No.1 speed sensor outputs a 4pulse signal for every revolution of the transaxle output shaft.
After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the Engine and ECT ECU.
4pulse
4pulse
From
Speed
Sensor
Engine and
ECT ECU
ABS ECU
Combination
Meter
A00022
DTC No.
P0500
Trouble Area
No vehicle speed sensor signal to Engine and ECT ECU during vehicle driving (2 trip detection logic)

S Combination meter
WIRING DIAGRAM
Engine and ECT ECU
Combination Meter
18
C10
J44
Junction
Connector
G
22
E20 SPD
D10040
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DI24
DIAGNOSTICS
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 is operating normally if the speedometer display is normal.
NG
Check speedometer circuit. See combination

meter troubleshooting.
OK
Check voltage between terminal SPD of Engine and ECT ECU connector and
body ground.
ON
()
(+)
SPD
D07192
PREPARATION:
(a) Turn up the floor mat on the passenger side.
(b) Remove the 2 bolts for Engine and ECT ECU.
(c) Shift the shift lever to N range.
(d) Jack up one of the front wheels.
(e) Turn ignition switch ON.
CHECK:
Measure voltage between terminal SPD of Engine and ECT
ECU connector and body ground when the wheel is turned
slowly.
OK:
Voltage is generated intermittently.
4.5 5.5 V
Turn the wheel

D02247
NG
Check and repair harness and connector between combination meter and Engine and ECT
ECU.
OK
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DI25
DIAGNOSTICS
Check Engine and ECT ECU (See page IN30).
NG
Replace Engine and ECT ECU.
OK
Check and repair ABS system.
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DI26
DIAGNOSTICS

DI1FV05
DTC
Shift Solenoid A/B Malfunction

(No. 1/No. 2 Solenoid Valve )
P0750, P0755
SYSTEM DESCRIPTION
The Engine and ECT ECU uses signals from the vehicle speed sensor and crankshaft position sensor to
detect the actual gear position (1st, 2nd, 3rd or O/D gear).
Then the Engine and ECT ECU compares the actual gear with the shift schedule in the Engine and ECT
ECU memory to detect the mechanical trouble of the shift solenoid valves, the valve body or automatic transaxle (clutch, brake or gear etc.).
DTC No.
Trouble Area
During normal driving, the gear required by the Engine and

ECT ECU does not match the actual gear
(2trip detection logic)
P0750
P0755
S No. 1/No. 2 solenoid valve is stuck open or closed

HINT:
Check the No. 1 solenoid valve when DTC P0750/62 is output and check the No. 2 solenoid valve when DTC
P0755/63 is output.
1
Check No. 1 or No. 2 solenoid valve operation.
()
()
(+)
(+)
Air
D04318
PREPARATION:
(a) Remove the oil pan.
(b) Remove the No. 1 or No. 2 solenoid valve .
CHECK:
(a) Applying 490 kPa (5 kgf/cm2, 71 psi) of compressed air,
check that the solenoid valve does not leak the air.
(b) When battery voltage is supplied to the shift solenoid
valve, check that the valve opens.
OK:
(a) Solenoid valve does not leak air.
(b) Solenoid valve opens.
NG
Replace the No. 1 or No. 2 solenoid valve.
OK
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DI27
DIAGNOSTICS
Check the valve body (See chapter 2 in the problem symptoms table).
NG
Repair or replace the valve body.
OK
Repair the transaxle (See page AX28).
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DI28
DIAGNOSTICS

DI1FW06
DTC
P0753,P0758
Shift Solenoid A/B Electrical Malfunction (No. 1/No. 2 Solenoid Valve)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is performed in combination with ON and OFF of the No. 1 and No. 2 solenoid valves
controlled by Engine and ECT ECU. If an open or short circuit occurs in either of the solenoid valves, the
Engine and ECT ECU controls the remaining normal solenoid valve to allow the vehicle to be operated
smoothly (Fail safe function).
NORMAL
Position
Solenoid valve
No.1
No.2
ON
OFF
ON
Gear
1st
ON
SHIFT SOLENOID NO.1

MALFUNCTIONING
Solenoid valve
Gear
No.1
No.2
X
ON
3rd
2nd
ON
SHIFT SOLENOID NO.2

MALFUNCTIONING
Solenoid valve
Gear
No.1
No.2
ON
X
1st
BOTH SOLENOID
MALFUNCTIONING
Gear when shift selector is
manually operated
O/D
3rd
OFF
O/D
O/D
OFF
ON
3rd
ON
3rd
OFF
O/D
O/D
OFF
OFF
O/D
OFF
O/D
OFF
O/D
O/D
ON
OFF
1st
ON
3rd
ON
1st
3rd
ON
ON
2nd
ON
3rd
OFF
O/D
3rd
OFF
ON
3rd
ON
3rd
OFF
O/D
3rd
ON
OFF
1st
OFF
1st
ON
1st
1st
ON
ON
2nd
ON
2nd
ON
1st
1st
X: Malfunctions
HINT:
Check the No. 1 solenoid valve when DTC P0753/62 is output and check the No. 2 solenoid valve when
DTC P0758/63 is output.
DTC No.
P0753
P0758

The Engine and ECT ECU checks for an open or short circuit
in the No. 1 or No. 2 solenoid valve circuit when it changes.
The Engine and ECT ECU records DTC P0753/62 or
P0758/63 if condition (a) or (b) is detected once, but it does not
blink the O/D OFF indicator light.
After Engine and ECT ECU detects condition (a) or (b) continuously 8 times or more in onetrip, it causes the O/D OFF indicator light to light up until condition (a) or (b) disappears.
After that, if the Engine and ECT ECU detects condition (a) or
(b) once, it starts lighting up O/D OFF indicator light again.
Trouble Area
S Open or short in No. 1/No. 2 solenoid valve circuit

S No. 1/No. 2 solenoid valve
(a) Solenoid resistance is 8 or less (short circuit) when the

solenoid is energized.
(b) Solenoid resistance is 100 k or more (open circuit) when
the solenoid is not energized.
Fail safe function:

If either of the solenoid valve circuits develops an open or short, the Engine and ECT ECU turns the other
solenoid valve ON and OFF to shift to the gear positions shown in the table above. The Engine and ECT
ECU also turns the ST solenoid valve OFF at the same time. If both solenoids malfunction, hydraulic control
cannot be performed electronically and must be done manually.
Manual shifting as shown in the above table must be done (In the case of a short circuit, the Engine and ECT
ECU stops sending current to the short circuited solenoid).
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DI29
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU
Transaxle
3
E1
LG
6
E1
VW
12
12
IE2 IF2
(RHD)(LHD)
11
11
IE2 IF2
(RHD)(LHD)
LG
8
E18 S1
VW
20
E18 S2
D10180
1
Measure resistance between terminal S1 or S2 of Engine and ECT ECU connector and body ground.
PREPARATION:
Disconnect the connector from Engine and ECT ECU.
CHECK:
Measure resistance between the terminal S1 or S2 of Engine
and ECT ECU connector and the body ground.
OK:
Resistance: 11 15 at 20C (68F)
S1
S2
D07193
OK
Check and replace Engine and ECT ECU (See

page IN30).
NG
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DI30
DIAGNOSTICS
Check harness and connector between Engine and ECT ECU and automatic
transaxle solenoid connector.
PREPARATION:
Disconnect the solenoid connector from the automatic transaxle.
CHECK:
Check harness and connector between the terminal S1 or S2
of Engine and ECT ECU and the terminal S1 or S2 of solenoid
connector.
OK:
There is no open and short circuit.
S1
S2
S1
S2
D08713
NG
Repair or replace harness or connector.
OK
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DI31
DIAGNOSTICS
Check No. 1 or No. 2 solenoid valve.

PREPARATION:
(a) Jack up the vehicle.
(b) Remove the oil pan.
(c) Disconnect the solenoid connector.
(d) Remove the No. 1 or No. 2 solenoid valve .
CHECK:
(a) Measure resistance between the solenoid connector and
the solenoid body.
(b) Connector positive lead to the terminal of solenoid connector, negative lead to the solenoid body.
OK:
(a) Resistance: 11 15 at 20C (68F)
(b) The solenoid makes an operating noise.
(+)
()
Q08083
Q08084
D04317
NG
Replace shift solenoid valve.
OK
Repair or replace solenoid wire.
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DI32
DIAGNOSTICS

DI1FX05
DTC
P0770
Shift Solenoid E Malfunction

(SL Solenoid Valve)
SYSTEM DESCRIPTION
Line
Pressure
Drain
The Engine and ECT ECU uses the signals from the throttle
position sensor, airflow meter and crankshaft position sensor
to monitor the engagement condition of the lockup clutch.
Then the Engine and ECT ECU compares the engagement
condition of the lockup clutch with the lockup schedule in the
Engine and ECT ECU memory to detect the mechanical trouble
of the shift solenoid valve SL, the valve body and the torque
converter or automatic transaxle (clutch, brake or gear etc.).
F01116
DTC No.
Trouble Area
P0770
S Lockup does not occur when driving in the lockup range

(normal driving at 80 km/h (50 mph)), or lockup remains ON
in the lockup OFF range.
S When lockup is ON, clutch or brake slips or gear is broken.
S SL solenoid valve is stuck open or closed

S Valve body blocked up or stuck
S Lockup clutch
1
Check SL solenoid valve operation.
()
()
(+)
Air
(+)
D04318
PREPARATION:
(b) Remove the SL solenoid valve from the valve body.
CHECK:
(a) Applying 490 kPa (5 km/cm2, 71 psi) of compressed air,
check that the solenoid valve opens.
(b) When battery positive voltage is supplied to the shift solenoid valve, check that it does no leak air.
OK:
(a) Solenoid valve opens.
(b) Solenoid valve does not leak air.
NG
Replace the SL solenoid valve.
OK
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DI33
DIAGNOSTICS
Check valve body (See chapter 2 in the problem symptoms table).
NG
OK
Check torque converter (See page AX33).
NG
Replace the torque converter.
OK
Repair the transaxle.
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DI34
DIAGNOSTICS

DI1FY06
DTC
P0773
Shift Solenoid E Electrical Malfunction

(SL Solenoid Valve)
CIRCUIT DESCRIPTION
The SL solenoid valve is turned ON and OFF by signals from the Engine and ECT ECU to control the hydraulic pressure acting on the lockup relay valve, then the signals control operation of the lockup clutch.
Fail safe function
If the Engine and ECT ECU detects a malfunction, it turns the SL solenoid valve OFF.
DTC No.
Trouble Area
P0773
Either (a) or (b) is detected for 1 time.

(a) Solenoid resistance is 8 or less for short circuit when
solenoid is energized.
(b) Solenoid resistance is 100 k or more for open circuit when
solenoid is not energized.
S Open or short on SL solenoid valve circuit

S SL solenoid valve
WIRING DIAGRAM
Engine and ECT ECU
Transaxle
SL Solenoid
Valve
2
E1
3
3
IE2 IF2
(RHD) (LHD)
19
E18 SL
D10181
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DI35
DIAGNOSTICS
1
Measure resistance between terminal SL of Engine and ECT ECU and body
ground.
PREPARATION:
CHECK:
Measure resistance between the terminal SL of Engine and
ECT ECU and the body ground.
OK:
Resistance: 11 15
SL
D07195
OK
Check and replace the Engine and ECT ECU

(See page IN30).
NG
PREPARATION:
Disconnect the solenoid connector from the transaxle.
CHECK:
Check the harness and connector between the terminal SL of
Engine and ECT ECU and the terminal 2 of solenoid connector.
OK:
There is no open or short circuit.
SL
2
D07196
NG
Repair or replace the harness or connector.
OK
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DI36
DIAGNOSTICS
Check SL solenoid valve.

PREPARATION:
(c) Disconnect the SL solenoid valve connector.
(d) Remove the SL solenoid valve.
CHECK:
(a) Measure resistance between the terminal SL of shift solenoid valve and the solenoid body.
(b) Connect positive (+) lead to the terminal of solenoid connector, negative () lead to the solenoid body.
OK:
(a) Resistance: 11 15
(b) The SL solenoid valve makes operation noise.
(+)
()
Q08086
Q08087
D04319
NG
Replace the SL solenoid valve.
OK
Check and replace or repair the solenoid

wire.
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DI37
DIAGNOSTICS

DI80B01
DTC
P1520
Stop Light Switch Signal Malfunction
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lockup condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signals to Engine and ECT ECU. Then the Engine
and ECT ECU cancels operation of the lockup clutch while braking is in progress.
DTC No.
Trouble Area
S Open or short in stop light switch circuit
S Stop light switch
No stop light switch signal to Engine and ECT ECU during

driving.
P1520
WIRING DIAGRAM
Sedan:
Instrument Panel J/B

STOP
1
10
IA
IG
WR *5
W *6
Stop Light
Switch
W
21
3F
8
3D
GW
6
E20 STP
8 3C
1 F17
FL
Block
Center J/B
GW
1
Engine and
ECT ECU
GW
GW
ALT
F *1
1 F15
F *1
6
5
ID1 II1
*5 *6
GW
J/C
W
FL
MAIN
1
2
High D *2 D *2 GW
Mounted GW
2
6
Stop
Stop
Stop Light
Light
Light RH
LH
4 WB
WB 4
A *4
Battery
A *4 A *4
J/C
A *3
WB
WB
A *3
*1: J12 (LHD), J28 (RHD)

*2: J13 (LHD), J29 (RHD)
*3: J10 (LHD), J30 (RHD)
*4: J11 (LHD), J31 (RHD)
*5: LHD
*6: RHD
WB
BL *5
BN *6
BM
F13602
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DI38
DIAGNOSTICS
Lift Back (LHD):

Stop Light
Switch

STOP
1
10
IA
IG
WR
W
1
8
3D
GW
6
E20 STP
8 3C
1 F17
FL
Block
21
3F
GW
2
Engine and
ECT ECU
Center J/B
GW
ALT
6
ID1
GW
GW
D J14 D J14
1 BD1
1 F15
J/C
F J15 F J15
GW
High
FL
Mounted GW
1 Stop
5
3
MAIN
Stop
Stop Light
Light
Light RH
LH
2
3 WB
5 WB
E J15
E J15 B J15
J/C
Battery WB
GW
E J14
WB
WB
E J14 B J14
WB
BO
BQ
BP
Lift Back (RHD):

Stop Light
Switch

STOP
1
10
IA
IG
Center J/B
21
3F
GW
W
2
Engine and
ECT ECU
8
3D
GW
6
E20 STP
FL
Block
1 F17
GW
ALT
GW
E J33 D J32
1 BD1
1 F15
W
FL
MAIN
Battery
GW E J33 E J33
High
GW
Mounted
1
3
Stop
Stop
Light LH
Light
2
5
WB
BQ
WB
BP
8 3C
5
II1
GW
J/C
GW
5
Stop Light
RH
3
WB
BO
F13603
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DI39
DIAGNOSTICS
Wagon:
WR *1
W *2

STOP
1
10
IA
IG
1 F17
FL
Block
Stop Light
Switch
J16 *1
J34 *2
ALT
6
5
ID1 II1
*1 *2
GW
B
21
3F
8
3D
GW
6
E20 STP
8 3C
GW
J17 *1
J35 *2
1 F15
W
Center J/B
GW
Engine and
ECT ECU
GW
FL
MAIN
1
2
A
C
C
High
Mounted GW
2 Stop
Stop
Light
Light LH
4
WB
A WB
Battery
A WB
BR
GW
2
Stop Light
RH
4
A WB J17 *1
J35 *2
Junction Connector
A WB
BS
*1: LHD
*2: RHD
F13604
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DI40
DIAGNOSTICS
HINT:
Read freeze frame data using handheld tester. Because freeze frame records the engine conditions when
the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the airfuel ratio lean or rich, etc. at the time of the malfunction.
Check operation of stop light.
PREPARATION:
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

(See Pub. No. RM599E BE section).
OK
Check STP signal.

ON
Brake Pedal
Depressed
Brake Pedal
Released
STP
()
(+)
When using handheld tester:

PREPARATION:
(a) Connect the handheld tester to the DLC3.
(b) Turn the ignition switch ON and handheld tester main
switch ON.
CHECK:
Read the STP signal on the handheld tester.
OK:
Brake pedal is depressed: STP ... ON
Brake pedal is released:
STP ... OFF
When not using handheld tester:
PREPARATION:
Turn the ignition switch ON.
CHECK:
Check voltage between terminal STP of Engine and ECT ECU
and body ground.
OK:
D08714
OK
Brake pedal
Voltage
Depressed
7.5 14 V
Released
Below 1.5 V
Check for intermittent problems (See page

DI18).
NG
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DI41
DIAGNOSTICS
Check harness and connector between Engine and ECT ECU and stop light
switch (See page IN30).
NG
OK

page IN30).
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DI42
DIAGNOSTICS

DI61W05
DTC
P1760
Linear Solenoid for Line Pressure Control

Circuit malfunction (SLT Solenoid Valve)
CIRCUIT DESCRIPTION
Line Pressure Control Pressure
Current Flow to Solenoid D02635
ON
OFF
1 cycle
The throttle pressure that is applied to the primary regulator

valve (which modulates line pressure) causes the SLT solenoid
valve, under electronic control, to precisely and minutely modulates and generates line pressure according to the accelerator
pedal effort, or engine power output detected.
This reduces the function of line pressure and provides smooth
shifting characteristics.
Upon receiving the throttle valve opening angle signal, Engine
and ECT ECU controls the line pressure by sending a predetermined (*) duty ratio to the solenoid valve, modulating the line
pressure, generating throttle pressure.
(*) Duty Ratio
The duty ratio is the ratio of the period of continuity in one cycle.
For example, if A is the period of continuity in one cycle, and B
is the period of noncontinuity, then
Duty Ratio =
BE4056
DTC No.
P1760

(a) or (b) condition below is detected for 1 second or more.
(a) SLT terminal: 0V
(b) SLT terminal: 12V
A
A+B
x 100 (%)
Trouble Area
HINT:
Refer to the chart for the wave form between terminals SLT+
and SLT during engine idling.
5 V / Div.
GND
1 msec. / Div.
D01875
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DI43
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU
Transaxle
1
E1
LGB
4
E1
PB
2
2
IE2 IF2
(RHD) (LHD)
LGB
6
E18 SLT+
PB
5
E18 SLT
SLT
Solenoid
Valve
1
1
IE2 IF2
(RHD)(LHD)
D10182
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DI44
DIAGNOSTICS
1
Check SLT solenoid valve.
1
(+)
()
2
D01888
D01889
D01887
D02235
PREPARATION:
Check solenoid resistance:
CHECK:
Measure resistance between terminals 1 and 2 of solenoid connector.
OK:
Resistance: 5.0 5.6 at 20 C (68F)
Check solenoid operation:
CHECK:
Connect positive (+) lead with an 8 10 W bulb to terminal 1 of
solenoid connector and negative () lead to terminal 2, then
check the movement of the valve.
OK:
When battery voltage is applied.
Valve moves in
direction
When battery voltage is cut off.
Valve moves in
direction
NG
Replace SLT solenoid valve.
OK
Check harness and connector between SLT solenoid valve and Engine and ECT
ECU (See page IN30).
NG
OK

page IN30).
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DI45
DIAGNOSTICS

DI80C01
DTC
P1780
Neutral Start Switch Malfunction
CIRCUIT DESCRIPTION
The neutral start switch detects the shift lever range and sends the signals to the Engine and ECT ECU.
The Engine and ECT ECU receives the signals (NSW, R, 2 and L) from the neutral start switch, when the
signal is not sent to the Engine and ECT ECU from the neutral start switch, the Engine and ECT ECU judges
that the shift lever is in the D range.
DTC No.
Trouble Area
2 or more switches are ON simultaneously for N, R, 2 or

L range.
P1780
When driving under the conditions (a), (b) and (c) for 30 seconds or more, the park/neutral position switch is ON (N position).
(a) Vehicle speed: 80 km/h (50 mph) or more
(b) Engine speed: 1,500 5,000 rpm
(c) Manifold absolute pressure: 300 mmHg or more

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DI46
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU
LL 8
YG
12
E20 L
2L 4
3
E20 2
RL
Center J/B
3
3C
RB
RL 2
3
3D
RB
2
E20 R
20
3D
BW
13
E20 NSW
Center J/B
6
7
3E
BW
20 3E
WB
BW
Center J/B
10
3C
10
3A
RL

GAUGE
10
5
IC
IF

ST
4
6
IC
IE
Ignition Switch
BY
5
8 IG1 AM1
R
WR
3 ST2 AM2 4
1
ID
2
ID
BW
Engine Room J/B
WR
3 2A
MAIN
6
2A
1
2D
A
J9 *1 J20 *2
Junction
Connector
IJ *1
II *2
Starter Relay
To Starter
6
2C
2H
W
W
Battery
AM2
1
FL Block 2 *1
1 *2
1
ALT
F15
F17

AM1
2
3
1
2
IA
IC
FL MAIN
*1: LHD
*2: RHD
D10185
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DI47
DIAGNOSTICS
1
Read NSW, REVERSE, 2ND and LOW signals.

PREPARATION:
(b) Turn the ignition switch ON.
CHECK:
Shift the shift lever to the P, R, N, 2 and L ranges, and read the
NSW, REVERSE, 2ND and LOW signals on the handheld tester.
OK:
Shift range
NSW
L
()
OFF ON
P, N
NSW
REVERSE
OFF ON
2ND
OFF ON
LOW
OFF ON

PREPARATION:
CHECK:
Measure voltage between the terminals NSW, R, 2 and L of Engine and ECT ECU and the body ground when the shift lever
is shifted to the following ranges.
OK:
ON
2
Signal
(+)
D07198
Range
P, N
NSWBody
ground
0V
RBody
ground
2Body
ground
LBody
ground
0V
0V
0V
0V
0V
0V
0V
7.5 14 V*
7.5 14 V*
7.5 14 V
0V
7.5 14 V
0V
7.5 14 V
0V
7.5 14 V
0V
0V
7.5 14 V
*: The voltage will drop slightly due to lighting up of the back up

light.
OK

page IN30).
NG
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DI48
DIAGNOSTICS
Check neutral start switch.

PREPARATION:
(b) Remove the neutral start switch.
CHECK:
Check continuity between each terminal shown below when the
shift lever is moved to each range.
5 4 32 1
9 8 7 6
Shift Range
D06561
Terminal No. to continuity
69
23
69
34
38
OK:
There is continuity.
NG
Replace the neutral start switch.
OK
Repair or replace harness and connector between battery and neutral start switch, neutral start
switch and Engine and ECT ECU (See page IN30).
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DI49
DIAGNOSTICS

DI80D01
O/D Main Switch & O/D OFF Indicator Light Circuit

CIRCUIT INSPECTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed once
again. In O/D main switch OFF position, the O/D OFF indicator light lights up, and the Engine and ECT ECU
prohibits shifting to O/D.
WIRING DIAGRAM
O/D OFF Indicator Light
(Combination Meter)
9
8
C11
C11
Engine and ECT ECU

L
BO
Center J/B
10
3F
19
E20 OD2
O/D Main Switch
10
3A
RL
Center J/B

5
IC
GAUGE
13
3A
10
IF
WB
13
3C
BY
WB
Ignition Switch
8
5
AM1
IG1
IE 4
W
Instrument
Panel
J/B

2
IA
W
*1
*2
2
1
F17
AM1
3
IC
WB
FL
Block
ALT
IC 1
1
F15
FL
MAIN
A J1 (LHD)
J27 (RHD)
Junction Connector
*1: LHD
*2: RHD
Battery
II (LHD)
IJ (RHD)
D10177
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DI50
DIAGNOSTICS
O/D OFF indicator light does not light up
1
Check O/D main switch.

PREPARATION:
Disconnect the O/D main switch connector.
CHECK:
Check continuity between the terminals 2 and 4 of the O/D main
switch connector.
OK:
Q08078
NG
O/D main switch
Specified condition
ON
No continuity
OFF
Continuity
Replace the O/D main switch.
OK
Check and replace the combination meter (See page BE1).
NG
Replace the combination meter.
OK
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DI51
DIAGNOSTICS
Check OVERDRIVE CUT SW2 signal.

PREPARATION:
(a) Connect a handheld tester to the DLC3.
(b) Turn the ignition switch ON and the handheld tester
main switch ON.
CHECK:
Read the OVERDRIVE CUT SW2 signal on the handheld tester.
OK:
(+)
OVERDRIVE CUT SW2 signal
O/D ON (Pushed in)
OFF
O/D OFF (Pushed once again)
ON

PREPARATION:
CHECK:
Check voltage between the terminal OD2 of Engine and ECT
ECU and the body ground.
OK:
ON
()
O/D main switch condition
OD2
D07199
OK
O/D main switch
Voltage
ON
Below 3 V
OFF
9 14

(See page IN30).
NG
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DI52
DIAGNOSTICS
Check harness and connector between O/D OFF indicator light and Engine and
ECT ECU (See page IN30).
PREPARATION:
Disconnect the connector (E6) of Engine and ECT ECU and the
connector (C14) of the combination meter.
CHECK:
Measure the continuity between the connector (E6) of Engine
and ECT ECU and the connector (C14) of the combination meter.
OK:
Continuity
NG
OK
Repair or replace the wire harness or connectors between the connector of Engine
and ECT ECU and the body ground.
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DI53
DIAGNOSTICS
O/D OFF indicator light remains ON

1

PREPARATION:
CHECK:
Check continuity between the terminals 2 and 4 of O/D main
switch connector.
OK:
Q08078
NG
O/D main switch
Resistance
ON
No continuity
OFF
Continuity
Repair the O/D main switch.
OK
Check harness and connector between O/D OFF indicator light and O/D main
switch, O/D OFF indicator light and Engine and ECT ECU (See page IN30).
NG
OK

(See page IN30).
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DI54
DIAGNOSTICS

DI33603
Pattern Select Switch Circuit

CIRCUIT DESCRIPTION
The Engine & ECT ECU memory contains the shift programs for the NORMAL, POWER and SNOW (w/
SNOW mode) patterns, 2 range, L range and the lockup patterns. By following the programs corresponding
to the signals from the pattern select switch, the neutral start switch and other various sensors, the Engine
& ECT ECT switches the solenoid valves ON and OFF, and controls the transaxle gear change and the lock
up clutch operation.
WIRING DIAGRAM
NORM 5
3
E5
E5
SNOW
2
E5
PWR
RL
Engine and ECT ECU

16
E20 SNWI
PB
Center J/B
15
15
3D
3B
28
E20 PWR
15 3F
Combination Meter
P
BO
3F 10
10 3B
3F 1
ECT SNOW
22
C11
Center
J/B
10 3A
7
22
RY
E21 SNWO
C10
9
C11
14
WB
C10
24
C10
ECT PWR
BO
1
WB
C10
RL
GAUGE
10
IF
5
IC
Ignition Switch
BY 8
WB
5
IG1
AM1
J1 *1
J27 *2
Junction
Connector
W
3
IC
AM1
2
2
IA
FL
2 *1 Block
1 *2
ALT
F17
1
F15
*1: LHD
*2: RHD
FL
MAIN
Battery
II *1
IJ *2
D10184
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DI55
DIAGNOSTICS
1
Check PATTERN SEL SW signal.

PREPARATION:
(a) Remove the DLC3 cover.
(b) Connect a handheld tester to the DLC3.
(c) Turn the ignition switch ON and handheld tester main
switch ON.
CHECK:
Read the PATTERN SEL SW signal on the handheld tester.
OK:
ON
PWR
SNWI
D10187
Pattern select switch
PATTERN SEL SW signal
POWER
ON
NORM
OFF
SNOW
OFF

PREPARATION:
CHECK:
Measure voltage between terminal each of PWR, SNWI of Engine & ECT ECU and body ground when the pattern select
switch is set to the PWR (POWER), NORM (NORMAL) or
SNOW (SNOW) position.
OK:
Switch position
Tester connection
Specified condition
PWR Body ground
9 14 V
SNWI Body ground
Below 1.5 V
PWR Body ground
Below 1.5 V
SNWI Body ground
Below 1.5 V
PWR Body ground
Below 1.5 V
SNWI Body ground
9 14 V
PWR
NORM
SNOW
HINT:
The Engine & ECT ECU uses the normal pattern signal if the
PWR and SNWI signals are not input.
OK
Proceed to next circuit inspection shown in

symptom problems table (See page DI18).
NG
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DI56
DIAGNOSTICS
Check pattern select switch

PREPARATION:
Disconnect the pattern select switch connector.
CHECK:
Check continuity between terminals 2 and 3 (PWR, NORM), 3
and 5 (SNOW) of pattern select switch connector when the select switch is set to PWR, NORM or SNOW position.
OK:
2
3
Switch position
Tester connection
Specified condition
PWR
23
Continuity
NORM
2 3, 3 5
No continuity
SNOW
35
Continuity
D10186
NG
Replace the pattern select switch.
OK
Check harness and connector between battery and pattern select switch, pattern
select switch and Engine & ECT ECU (See page IN30).
NG
OK
Check and replace the Engine & ECT ECU

(See page IN30).
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DI57
DIAGNOSTICS

DI80E01
Kickdown Switch Circuit (LHD)

CIRCUIT DESCRIPTION
The kickdown switch is turned ON when the accelerator pedal is depressed beyond the full throttle opening
and sends signals to Engine and ECT ECU.
When the kickdown switch is turned ON, the Engine and ECT ECU controls gear shifting according to the
programmed shift diagrams.
If a short circuit develops in the kickdown switch, the Engine and ECT ECU disregards the kickdown signals and controls shifting at the normal shift points.
WIRING DIAGRAM
Engine and ECT ECU

Kickdown
Switch
4
1
E20 KD
WB
Center J/B

WB
1
IC
4
IE
WB
22
3F
9
3F
13
3A
4
3F
WB
J1 (LHD)
J27 (RHD)
Junction
Connector
II (LHD)
IJ (RHD)
D10183
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DI58
DIAGNOSTICS
1
Check KICK DOWN SW signal.

PREPARATION:
switch ON.
CHECK:
Read the KICK DOWN SW signal on the handheld tester.
OK:
Accelerator Pedal
()
Fully depressed (kickdown SW is ON)
ON
Released (kickdown SW is OFF)
OFF

PREPARATION:
CHECK:
Measure voltage between terminal KD of Engine and ECT ECU
connector and body ground when accelerator pedal is fully depressed or not.
OK:
KD
ON
KICK DOWN
SW signal
(+)
D07200
Accelerator Pedal
Voltage
Fully depressed (kickdown SW is on)
Below 1 V
10 14 V
OK

problem symptoms table (See page DI18).
NG
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DI59
DIAGNOSTICS
Check kickdown switch.

PREPARATION:
Disconnect the kickdown switch connector.
CHECK:
Check continuity at each terminal of kickdown switch connector.
OK:
2
D01519
NG
Kickdown Switch
Specified continuity
ON
Continuity
OFF
No continuity
Replace kickdown switch
OK
Check harness and connector between Engine & ECT ECU and kickdown
switch, kickdown switch and body ground (See page IN30).
NG
OK
Check and replace Engine & ECT ECU (See

page IN30).
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DI60
DIAGNOSTICS

DI2L411

1
are titles of pages in this manual, with the

Items inside
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.

P. DI61
Connect the handheld tester to DLC3.

If the display shows UNABLE TO CONNECT TO VEHICLE when you have connected the
handheld tester, inspect DLC3 P. DI62
Check DTC and Freeze Frame Data (Precheck)

Record or Print DTC and Freeze Frame Data P DI62
4
5
6
Clear DTC and Freeze Frame Data P. DI74

Visual Inspection
Setting the Check Mode Diagnosis P. DI62
Symptom does not occur

7
Symptom Simulation
P. IN20
Symptom occur
9
10
DTC Check
P. DI62
OK Code
11
Basic Inspection
12
DTC Chart
P. DI74
OK
14
OK
OK
13
NG
Manual Shifting Test

P. DI62
Chapter 2
(OnVehicle)
OK
P. DI79
OK
Chapter 3
(OffVehicle)
NG
P. DI79
P. DI79
NG
NG
Circuit
Inspection
NG
Mechanical System Test

P. DI62
Problem Symptoms Table P. DI79

Chapter 1
(Electronic)
15
NG
P. DI62
S Neutral Start Switch Circuit (Except Europe) Check

S Kickdown Switch Circuit Check
16
Parts Inspection
P. DI82 to DI124
17
18
Repair
Confirmation Test
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End
DI61
DIAGNOSTICS

DI2L506

Automatic Transaxle
System Check Sheet
Inspectors
Name
Registration No.
Customers Name
Registration Year
Frame No.
Date Vehicle
Brought In
Date Problem
Occurred
How Often Does

Problem Occur?
/
Intermittent (
Continuous
Vehicle does not move (
No upshift
No downshift
Any range
1st 2nd
km
mile
Odometer Reading
O/D 3rd
times a day)
Particular range)
2nd 3rd
3rd 2nd
3rd O/D)
2nd 1st)
Lockup malfunction
Symptoms
Harsh engagement (
ND
Lockup
Any drive range)
Slip or shudder
No kickdown
Others
Check Item
Malfunction
Indicator Lamp
Normal
1st Time
Normal code
Malfunction code (DTC
2nd Time
Normal code
Malfunction code (DTC
Remains ON
DTC Check
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DI62
DIAGNOSTICS

DI80F01
PRECHECK
1.
(a)
DIAGNOSIS SYSTEM
Description
S
When troubleshooting EuroOBD vehicles, the
only difference from the usual troubleshooting procedure is that you connect an OBD scan tool complying with ISO150314 or handheld tester to the
vehicle, and read off various data output from the
vehicles engine and ECT ECU.
S
EuroOBD regulations require that the vehicles

onboard computer lights up the check engine
warning light (CHK ENG) on the instrument panel
when the computer detects a malfunction in the
computer itself or in drive system components
which affect vehicle emissions. In addition to the
CHK ENG lighting up when a malfunction is detected, the applicable DTCs prescribed by
ISO150316 are recorded in the engine and ECT
ECU memory (See page DI74).
If the malfunction only occurs in 3 trips, the CHK
ENG goes off but the DTCs remain recorded in the
engine and ECT ECU memory.
To check the DTCs, connect an OBD scan tool or

handheld tester to the Data Link Connector
(DLC3) on the vehicle. The OBD scan tool or hand
held tester also enables you to erase the DTCs and
check freeze frame data and various forms of engine data (For instruction book).
DTCs include ISO controlled codes and manufacturer controlled codes.
ISO controlled codes must be set as prescribed by
the ISO, while manufacturer controlled codes can
be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI74).
A13822
Handheld Tester
DLC3
D01600
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DI63
DIAGNOSTICS
(b)
The diagnosis system operates in normal mode

during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most DTCs use
2 trip detection logic(*) to prevent erroneous detection. By switching the engine and ECT ECU to
check mode when troubleshooting, the technician
can cause the CHK ENG to light up and for a malfunction that is only detected once or momentarily
(handheld tester) (See page DI62).
*2 trip detection logic:
When a logic malfunction is first detected, the malfunction is temporarily stored in the engine and ECT
ECU memory. If the same malfunction is detected
again during the 2nd test drive, this 2nd detection
causes the CHK ENG to light up .
Inspect the DLC3.

The vehicles engine and ECT ECU uses ISO 91412 for
communication. The terminal arrangement of DLC3 complies with ISO150313 and matches the ISO 91412 format.
1 2 3 4 5 6 7 8
9 10111213141516
DLC3
A04550
Tester connection
7 (Bus Line) 5 (Signal ground)
Condition
Specified condition
Pulse generation
4 (Chassis Ground) Body
Always
1 or less
16 (B+) Body
Always
9 14 V
HINT:
when you have connected the cable of OBD scan tool or hand
held tester to the DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool
side.
S
S
If communication is still not possible when the tool is connected connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department
listed in the tools instruction manual.
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DI64
DIAGNOSTICS
2.
(a)
A13822
Handheld Tester
DLC3
D01600
INSPECT DIAGNOSIS (Normal Mode)

Check the CHK ENG.
(1) The CHK ENG comes on when the ignition switch
is turned ON and the engine is not running.
HINT:
If the CHK ENG does not light up, troubleshoot the combination
meter (See page BE1).
(2) When the engine is started, the CHK ENG should
go off. If the lamp remains on, the diagnosis system
has detected a malfunction or abnormality in the
system.
(b) Check the DTC.

NOTICE:
Handheld tester only: When the diagnostic system is
switched from the normal mode to the check mode, it
erases all DTCs and freeze frame data recorded in normal
mode. So before switching modes, always check the DTCs
and freeze frame data, and note them down.
(1) Prepare an OBD scan tool or handheld tester.
(2) Connect the OBD scan tool or handheld tester to
the DLC3 at the lower of the instrument panel.
(3) Turn the ignition switch ON and push the OBD scan
tool or handheld tester switch ON.
(4) Use the OBD scan tool or handheld tester to check
the DTCs and freeze frame data and note them
down (For operating instructions, see the OBD scan
tools instruction book).
(5) See page DI74 to confirm the details of the DTCs.
NOTICE:
When simulating symptoms with an OBD scan tool (excluding handheld tester) to check the DTCs, use normal
mode. For codes on the DTCs chart subject to 2 trip detection logic, turn the ignition switch OFF after the symptom
is simulated the 1st time. Then repeat the simulation process again. When the problem has been simulated twice,
the CHK ENG is indicated on the instrument panel and
DTCs are recorded in the engine and ECT ECU.
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DI65
DIAGNOSTICS
3.
INSPECT DIAGNOSIS (Check Mode)
HINT:
Handheld tester only: Compared to the normal mode, the
check mode has high sensing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
Normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Check the initial conditions.
S
Battery positive voltage 11 V or more.
S
Throttle valve fully closed.
S
Transaxle in P position.
S
A/C switched off.
Handheld Tester
(4)
(5)
Connect the handheld tester to DLC3 at the lower

of the instrument panel.
Turn the ignition switch ON and switch the hand
held tester ON.
DLC3
D01600
(6)
0.13 sec.
(7)
0.13 sec.
ON
(8)
OFF
BR3904
Switch the handheld tester from normal mode to

check mode (Check that the CHK ENG flashes).
Start the engine (CHK ENG goes out after the engine starts).
Simulate the conditions of the malfunction described by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(9) After simulating the malfunction conditions, use the
handheld tester diagnosis selector to check the
DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF, as turning it off
switches the diagnosis system from check mode to normal
mode, so all DTCs, etc. are erased.
(10) After checking the DTC, inspect the applicable circuit.
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DI66
DIAGNOSTICS
(b)
Clear the DTC.

The following actions will erase the DTC and freezed
frame data. Operating an OBD scan tool or handheld
tester to erase the codes (See the OBD scan tools
instruction book for operating instructions.).
4.
PROBLEM SYMPTOM CONFIRMATION
Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the
trouble. If the problem is that the transaxle does not shift up, shift down, or the shift point is too high or too
low conduct the following road test referring to the automatic shift schedule and simulate the problem symptoms.
5.
ROAD TEST
NOTICE:
Conduct the test at normal operating ATF temperature 50 80 C (122 176 F).
(a) D range test
Shift into the D range and fully depress the accelerator pedal and check the following points:
Check to see that 1 2, 2 3 and 3 O/D upshift takes place, and that the shift points conform to the automatic shift schedule (See page SS23).
HINT:
S
O/D Gear Upshift Prohibition Control (1. Water temp. is 60 C (140 F) or less. 2. If there is a 10 km/h
(6 mph) difference between the set cruise control speed and vehicle speed.)
S
O/D Gear Lockup Prohibition Control (1. Brake pedal is depressed. 2. Water temp. is 60 C (140 F)
or lower)
(2) Check for shift shock and slip.
Check for shock and slip at the 1 2, 2 3 and 3 O/D upshift.
(3) Check for abnormal noises and vibration.
Run in D range lockup or O/D gear and check for abnormal noises and vibration.
HINT:
The check for the cause of abnormal noises and vibration must be done very thoroughly as it could also be
sure to loss of balance in the differential, torque converter, etc.
(4) Check kickdown operation.
While running in the D range, 2nd, 3rd and O/D gears, check to see that the possible kickdown
vehicle speed limits for 2 1, 3 2 and O/D 3 kickdowns conform to those indicated in the
automatic shift schedule (See page SS23).
(5) Check for abnormal shock and slip at kickdown.
(6) Check the lockup mechanism.
S
Drive in D range O/D gear, at a steady speed (lockup ON) of about 60 km/h (37 mph).
S
Lightly depress the accelerator pedal and check that the engine speed does not change
abruptly.
If there is a big jump in engine speed, there is no lockup.
(b) 2 range test
Shift into the 2 range and fully depress the accelerator pedal and check the following points:
Check to see that the 1 2 upshift takes place and that the shift point conforms to the automatic
shift schedule (See page SS23).
HINT:
There is no O/D upshift and lockup in the 2 range.
While running in the 2 range and 2nd gear, release the accelerator pedal and check the engine
braking effect.
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DI67
DIAGNOSTICS
(3)
Check for abnormal noises during acceleration and deceleration, and for shock at upshift and
downshift.
(c) L range test
Shift into the L range and fully depress the accelerator pedal and check the following points:
(1) Check no upshift.
While running in the L range, check that there is no upshift to 2nd gear.
While running in the L range, release the accelerator pedal and check the engine braking effect.
(3) Check for abnormal noises during acceleration and deceleration.
(d) R range test
Shift into the R range and fully depress the accelerator pedal and check for slipping.
CAUTION:
Before conducting this test ensure that the test area is free from people and obstruction.
(e) P range test
Stop the vehicle on a grade (more than 5) and after shifting into the P range, release the parking
brake. Then, check to see that the parking lock pawl holds the vehicle in place.
6.
BASIC INSPECTION
(a) Check the fluid level.
HINT:
Drive the vehicle so that the engine and transaxle are at normal
operating temperature.
Fluid temperature: 70 80 C (158 176 F)
(1)
(2)
(3)
(4)
Park the vehicle on a level surface and set the parking brake.
With the engine idling and the brake pedal depressed, shift the shift lever into all ranges from P
to L range and return to P range.
Pull out the dipstick and wipe it clean.
Push it back fully into the pipe.
D01529
(5)
Pull it out and check that the fluid level is in the HOT
range.
If the level is not within the range, add new fluid.
Fluid type: ATF Type TIV
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
OK if hot
Add if hot
AT3417
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DI68
DIAGNOSTICS
(c)
Replace the ATF.

(1) Remove the drain plug and drain the fluid.
(2) Reinstall the drain plug securely.
D07261
(3)
With the engine OFF add new fluid through the oil
filler pipe.
Fluid type: ATF Type TIV
Capacity: 4.1 liters (4.3 US qts, 3.6 Imp.qts)
(4) Start the engine and shift the shift lever into all
ranges from P to L range and then shift into P range.
AT8562
(5)
OK if hot
(6)
Add if hot
AT3417
With the engine idling, check the fluid level. Add

fluid up to the COOL level on the dipstick.
Check the fluid level at the normal operating temperature, 70 80 C (158 176 F), and add as
necessary.
NOTICE:
Do not overfill.
(d) Check the fluid leaks.
Check for leaks in the transaxle.
If there are leaks, it is necessary to repair or replace Orings,
FIPGs, oil seals, plugs or other parts.
(e)
D07258
Inspect and adjust the shift lever position.

When shifting the shift lever from the N range to other
positions, check that the lever can be shifted smoothly
and accurately to each range and that the position indicator is not aligned with the correct position.
If the indicator is not aligned with the correct position, carry out
the following adjustment procedures.
(1) Loosen the nut on the shift lever.
(2) Push the control shaft fully downward.
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DI69
DIAGNOSTICS
(3)
(4)
(5)
Return the control shaft lever 2 notches to N range.

Set the shift lever to N range.
While holding the shift lever lightly toward the R
range side, tighten the shift lever nut.
(6) Start the engine and make sure that the vehicle
moves forward when shifting the lever from the N to
D range and reverses when shifting it to the R
range.
N
R
P
D07260
Bolt
Neutral Basic
Line
Bolt
Groove
D07257
(f)
Inspect and adjust the neutral start switch.

Check that the engine can be started with the shift lever
only in the N or P range, but not in other ranges.
If it is not as stated above, carry out the following adjustment
procedures.
(1) Loosen the neutral start switch bolt and set the shift
lever to the N range.
(2) Align the groove and the neutral basic line.
(3) Holding the shift selector, and tighten the bolt.
HINT:
For continuity inspection of the neutral start switch, see page
DI112.
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DI70
DIAGNOSTICS
7.
(a)
MECHANICAL SYSTEM TESTS

Measure the stall speed.
The object of this test is to check the overall performance of the transaxle and engine by measuring
the stall speeds in the D and R ranges.
NOTICE:
S
S
Do not continuously run this test for longer than 5 seconds.
S
To ensure safety, do this test in a wide, clear level area which provides good traction.
S
The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is doing the test.
(3) Fully apply the parking brake.
(4) Keep your left foot pressing firmly on the brake pedal.
(6) Shift into the D range. Press all the way down on the accelerator pedal with your right foot.
(7) Quickly read the stall speed at this time.
(8) Do the same test in the R range.
Evaluation:
Problem
Possible cause
(a) Stall speed low in D and R ranges
S Engine output may be insufficient

S Stator oneway clutch not operating properly
HINT: If more than 600 rpm below the specified value, the torque
converter could be faulty.
(b) Stall speed high in D range

S Forward clutch slipping
S No.2 oneway clutch not operating properly
S O/D clutch slipping
(c) Stall speed high in R range

S Direct clutch slipping
S 1st & reverse brake slipping
S O/D clutch slipping
(d) Stall speed high in D and R ranges

S O/D oneway clutch not operating properly
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DI71
DIAGNOSTICS
(b)
Measure the time lag.

When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before
the shock can be felt. This is used for checking the condition of the O/D direct clutch, forward clutch,
and 1st & reverse brake.
NOTICE:
S
S
Be sure to allow 1 minute interval between tests.
S
Take 3 measurements and take the average value.
(3) Start engine and check idle speed.
Idle speed: 675 50 rpm (In N range and A/C OFF)
(4) Shift the lever from N to D range. Using a stop watch, measure the time from when the lever is
shifted until the shock is felt.
Time lag: N D less than 1.2 seconds
(5) In the same way, measure the time lag for N R.
Time lag: N R less than 1.5 seconds
Evaluation (If N D or N R time lag is longer than the specified):
Problem
Possible cause
N D time lag is longer

S Forward clutch worn
S O/D No. 2 oneway clutch not operating properly
N R time lag is longer

S Direct clutch worn
S 1st & reverse brake worn
S O/D oneway clutch not operating properly
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DI72
DIAGNOSTICS
8.
HYDRAULIC TEST
Measure the line pressure.
NOTICE:
S
Do the test at normal operation ATF temperature 50 80 C (122 176 F).
S
The line pressure test should always be carried out in pairs. One technician should observe
the conditions of wheels or wheel stopper outside the vehicle while the other is doing the test.
S
Be careful to prevent SSTs hose from interfering with the exhaust pipe.
(1) Warm up the ATF.
(2) Remove the test plug on the rear side of the transaxle case and connect SST (See page AX33
for the location to connect SST).
SST 0999200095 (09992 00231, 0999200271)
(3) Fully apply the parking brake and chock the 4 wheels.
(5) Start the engine and check idling speed.
(6) Keep your left foot pressing firmly on the brake pedal and shift into D range.
(7) Measure the line pressure when the engine is idling.
(8) Depress the accelerator pedal all the way down. Quickly read the highest line pressure when
engine speed reaches stall speed.
(9) In the same way, do the test in R range.
Specified line pressure:
Condition
D range
R range
Idling
372 412 (3.8 4.2, 54 59)
640 742 (6.5 7.6, 93 107)
Stall
931 1,031 (9.5 10.5, 134 149)
1,768 1,968 (18.0 20.1, 255 286)
Evaluation:
Problem
Possible cause
If the measured values at all ranges are higher
S Throttle valve defective

S Regulator valve detective
If the measured values at all ranges are lower
S Throttle valve defective

S Regulator valve defective
S Oil pump defective
S O/D direct clutch defective
If pressure is low in the D range only
S D range circuit fluid leakage

S Forward clutch defective
If pressure is low in the R range only
S R range circuit fluid leakage

S Direct clutch defective
S 1st & reverse brake defective
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DI73
DIAGNOSTICS
D09299
9.
MANUAL SHIFTING TEST
HINT:
By this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transaxle.
(a) Disconnect the solenoid wire.
(b) Inspect the manual driving operation.
Check that the shift and gear positions correspond to the
table below.
While driving, shift through the L, 2 and D ranges.
Check that the gear change corresponds to the shift
range.
Shift range
Gear position
O/D
O/D
1st
Reverse
Pawl Lock
HINT:
If the L, 2 and D range gear positions are difficult to distinguish,
do the above read test.
If any abnormality is found in the above test, the problem is in
the transaxle itself.
(c) Connect the solenoid wire.
(d) Cancel out the DTC.
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DI74
DIAGNOSTICS

DI6RF03

If a DTC is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the page given.
DTC No.
(See Page)
Detection Item
Trouble Area
Check engine
warning light *1
Memory*2
P0500
(DI82)
Vehicle Speed Sensor

Malfunction

S Combination meter
S Automatic transaxle assembly
P0710
(DI85)
Transmission Fluid Temperature

Sensor Malfunction
S Open or short in ATF temperature sensor circuit

S ATF temperature sensor
P0711 *3
(DI85)
Transmission Fluid Temperature

Sensor Rnge/Performance problem
S Open or short in ATF temperature sensor circuit

S ATF temperature sensor
P0750 *3
(DI87)
Shift Solenoid A Malfunction

(SL1 Solenoid Valve)
S SL1 solenoid valve is stuck open or closed

Shift Solenoid A Electrical Malfunction

S Open or short in SL1 solenoid valve circuit

S SL1 solenoid valve
Shift Solenoid B Malfunction

S SL2 solenoid valve is stuck open or closed

Shift Solenoid B Electrical Malfunction

S Open or short in SL2 solenoid valve circuit

S SL2 solenoid valve
Shift Solenoid D Malfunction

(S4 Solenoid Valve)
S S4 solenoid valve is stuck open or closed

Shift Solenoid D Electrical Malfunction

(S4 Solenoid Valve)
S Open or short in S4 solenoid valve circuit

S S4 solenoid valve

(DSL Solenoid Valve)
S DSL solenoid valve is stuck open or closed

S Lockup clutch
P0773
(DI97)

S Open or short in shift solenoid valve DSL circuit

S DSL solenoid valve
P1520
(DI100)
Stop Light Switch Circuit

S Stop light switch
P1725
(DI105)
NT Revolution Sensor Circuit

Malfunction
(Input Turbine Speed Sensor)
S Open or short in input turbine speed sensor circuit

S Input turbine speed sensor
P1730
(DI107)
NC Revolution Sensor Circuit

Malfunction
(Counter Gear Speed Sensor)
S Open or short in counter gear speed sensor circuit

S Counter gear speed sensor
P1760
(DI109)
Linear Solenoid for Accumulator

Pressure Control Circuit Malfunction
(SLT Solenoid Valve)

P1780
(DI112)

P0753
(DI89)
P0755 *3
(DI87)
P0758
(DI89)
P0765 *3
(DI87)
P0768
(DI89)
P0770 *3
(DI95)
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DI75
DIAGNOSTICS
*1: f mark means Check engine warning light blinks once every 2 seconds.
X mark means Check engine warning light never blinks.
*2: f mark means Engine and ECT ECU memorizes the malfunction code if the Engine and ECT ECU
detects the DTC detection condition.
*3: European spec. only
HINT:
This DTC may be output when the clutch, brake and gear components etc. inside the automatic transaxle
are damaged.
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DI76
DIAGNOSTICS

DI6TF03
PARTS LOCATION
Counter Gear
Speed Sensor
SLT Solenoid
Valve
Input Turbine
Speed Sensor
ATF Temperature
Sensor
SL1 Solenoid
Valve
Neutral Start
Switch
DSL Solenoid Valve

SL2 Solenoid Valve
S4 Solenoid Valve
O/D OFF Indicator

LHD:
Kickdown Switch
DLC3
Engine and ECT ECU

Stop Light Switch
O/D Main Switch

D09910
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DI77
DIAGNOSTICS

DI6RG03
TERMINALS OF ECU
E16
E17
E14
E15
E13
D03442
D01054
Wiring Color
STP (E1322)
(E13 22) E1 (E16
(E163)
3)
G W BR
GW
SL1+ ((E147)) SL1 (E146)

(
)
SL2+ ((E147)) SL2 ((E1416))
BW
GL
Condition
STD Voltage (V)
IG ON and brake pedal depressed
10 14
IG ON and brake pedal released
Below 1
IG ON
10 14
1st or 2nd gear
10 14
3rd or O/D gear
Below 1
IG ON
Below 1
1st or 2nd gear
10 14
3rd or O/D gear
Below 1
IG ON
Below 1
Vehicle driving under lockup position
10 14
DSL (E1425)
(E14 25) Body ground
P Body
ground
NC+ (E154) NC (E1510)
WB
Engine is running
Pulse signal is output

Below 1 4 5
NT+ (E155) NT (E1511)
GR
Engine is running

Below 1 4 5
SLT+ (E1415) SLT (E1424)

OD2 (E1311)
(E13 11) E1 (E163)
(E16 3)
R LW
L BR
L (E144)
(E14 4) E1 (E163)
(E16 3)
Y G BR
YG
2 (E1411)
(E14 11) E1 (E163)
(E16 3)
O BR
R (E141)
(E14 1) E1 (E163)
(E16 3)
R B BR
RB
D (E1410)
(E14 10) E1 (E16
(E163)
3)
B Y BR
BY
NSW (E1523)
(E15 23) E1 (E163)
(E16 3)
B W BR
BW
THO (E148) E2 (E1619)
O BR
S4 (E1426)
(E14 26) E1 (E163)
(E16 3)
Y BR
KD (E1317)
(E13 17) E1 (E163)
(E16 3)
Y BR
IG ON
10 14
O/D main switch ON
10 14
O/D main switch OFF
Below 1
IG ON and Shift lever L range
10 14
IG ON and Shift lever other than L range
Below 1
IG ON and Shift lever 2 range
10 14
IG ON and Shift lever other than 2 range
Below 1
IG ON and Shift lever R range
10 14
IG ON and Shift lever other than R range
Below 1
IG ON and Shift lever D range
10 14
IG ON and Shift lever other than D range
Below 1
IG ON and Shift lever P or N range
10 14
IG ON and Shift lever other than P or N range
Below 1
IG ON and ATF temperature 110 C (230 F)
Below 1
IG ON
Below 1
IG ON and O/D gear
10 14
IG ON and accelerator pedal is fully depressed

IG ON and accelerator is released
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Below 1.5
10 14
DI78
DIAGNOSTICS
IG ON and vehicle stationary

SPD (E136) E1 (E163)
G BR
PWR (E149)
(E14 9) E1 (E163)
(E16 3)
P BR
SNWI (E1419)
(E14 19) E1 (E163)
(E16 3)
P B BR
PB
Below 1
IG ON and turn one front wheel slowly

Below 1 4 6
IG ON and pattern select switch: PWR
9 14
IG ON and pattern select switch: NORM
Below 1
IG ON and SNOW mode switch: ON
9 14
IG ON and SNOW mode switch: OFF
Below 1.5
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DI79
DIAGNOSTICS

DI6RH03

If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the
circuits for each symptom in the order given in the charts on the following pages and proceed to the page
given for troubleshooting.
The Matrix Chart is divided into 3 chapters.
Chapter 2: Onvehicle repair matrix chart
Chapter 3: Offvehicle repair matrix chart
If the instruction Proceed to next circuit inspection shown on matrix chart is given in the flow chart for each
circuit, proceed to the circuit with the next highest number in the table to continue the check.
If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check and
replace the Engine and ECT ECU.
Symptom
Suspect Area
See page
No upshift (A particular gear, from 1st to 3rd gear, is not up

shifted)
1. Neutral start switch circuit

DI112
IN30
No upshift (3rd O/D)
1. O/D main switch circuit

DI116
IN30
No downshift (O/D 3rd)
Engine and ECT ECU
IN30
No downshift (A particular gear, from 3rd to 1st gear, is not

downshifted)
1. Neutral start switch circuit

DI112
IN30
No lockup or No lockup off
1. Stop light switch circuit

DI100
IN30
Engine and ECT ECU
IN30
Upshift to 2nd while in L range
Engine and ECT ECU
IN30
Upshift to 3rd while in 2 range
Engine and ECT ECU
IN30
Upshift to O/D from 3rd while O/D main switch is OFF
1. O/D main switch circuit

DI116
IN30
Upshift to O/D from 3rd while engine is cold
Engine and ECT ECU
IN30
Harsh engagement (N D)
Engine and ECT ECU
IN30
Harsh engagement (Lockup)
Engine and ECT ECU
IN30
Harsh engagement (Any driving range)
Engine and ECT ECU
IN30
Poor acceleration
Engine and ECT ECU
IN30
No kickdown
1. Kickdown switch circuit

DI124
IN30
Engine and ECT ECU
IN30
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DI80
DIAGNOSTICS
Chapter 2: Onvehicle repair

(L: U240E automatic transaxle repair manual Pub. No. RM740U)
Symptom
Suspect Area
See page
Vehicle does not move in any forward range and reverse range
1. Manual valve
3. Offvehicle repair matrix chart
L
L
Vehicle does not move in R range
Offvehicle repair matrix chart
No upshift (1st 2nd)
1. 12 shift valve
No upshift (2nd 3rd)
1. 23 shift valve
1. 34 shift valve
No downshift (O/D 3rd)
34 shift valve
No downshift (3rd 2nd)
23 shift valve
No downshift (2nd 1st)
12 shift valve

1. C1 accumulator
Harsh engagement (N R)
1. C2 accumulator

Harsh engagement (2nd 3rd)
C2 accumulator
Harsh engagement (3rd O/D)
B0 accumulator
Harsh engagement (O/D 3rd)
1. C0 accumulator
2. B0 accumulator
L
L
Slip or shudder (Forward and reverse)
1. Oil strainer
No engine braking (1st: L range)
No engine braking (2nd: 2 range)
No kickdown
1. 12 shift valve
2. 23 shift valve
3. 34 shift valve
L
L
L
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DI81
DIAGNOSTICS
Chapter 3: Offvehicle repair

(L: U240E automatic transaxle repair manual Pub. No. RM740U)
Symptom
Suspect Area
See page
Vehicle does not move in any forward range and reverse range
1.
2.
3.
4.
5.
Front and rear planetary gear

U/D planetary gear
Forward clutch (C1)
U/D brake (B3)
L
L
L
L
L
Vehicle does not move in R range
1.
2.
3.
4.
5.
Front and rear planetary gear unit

U/D planetary gear unit
Direct clutch (C2)
U/D brake (C3)
1st & reverse brake (B2)
L
L
L
L
L
No upshift (1st 2nd)
1. No. 1 oneway clutch (F1)

2. 2nd brake (B1)
L
L
No upshift (2nd 3rd)
Direct clutch (C2)
U/D clutch (C3)
Torque converter

3. No. 1 oneway clutch (F1)
L
L
L
Harsh engagement (N R)

2. 1st & reverse brake (B2)
L
L
Torque converter
AX38
Slip or shudder (Forward position: After warmup)
1.
2.
3.
4.
5.
6.
AX38
L
L
L
L
L
Slip or shudder (R range)

2. 1st & reverse brake (B2)
L
L
Slip or shudder (1st)
No. 1 oneway clutch (F1)
Slip or shudder (2nd)

2. 2nd brake (B1)
L
L
Slip or shudder (3rd)
Direct clutch (C2)
Slip or shudder (O/D)
U/D clutch (C3)
No engine braking (1st 3rd: D range)
U/D brake (B3)
No engine braking (1st: L range)
1st & reverse brake (B2)
No engine braking (2nd: 2 range)
2nd brake (B1)
Poor acceleration (All range)
1. Torque converter
2. U/D planetary gear
AX38
L
Poor acceleration (O/D)
1. U/D clutch (C3)

2. U/D planetary gear
L
L
Large shift shock or engine stalls when starting off or stopping
Torque converter
Torque converter
Forward clutch (C1)
Direct clutch (C2)
U/D brake (C3)
No. 1 oneway clutch (F1)
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AX38
AX38
DI82
DIAGNOSTICS

DI6RI03
CIRCUIT INSPECTION
DTC
P0500
Vehicle Speed Sensor Malfunction
CIRCUIT DESCRIPTION
The ABS ECU output the vehicle speed signals to a speedometer in the combination meter, and the signals
it is then transmitted to the Engine and ECT ECU. The Engine and ECT ECU determines the vehicle speed
based on the frequency of these pulse signals.
4pulse
4pulse
From
Speed
Sensor
Engine and
ECT ECU
ABS ECU
Combination
Meter
A00022
DTC No.
P0500
Trouble Area
No vehicle speed sensor signal to Engine and ECT ECU during vehicle driving (2 trip detection logic)

S Combination meter
WIRING DIAGRAM
Engine and ECT ECU
Combination Meter
18
C10
J44
Junction
Connector
G
6
E13 SPD
D10040
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DI83
DIAGNOSTICS
1
Check operation of speedometer.
HINT:
the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the airfuel ratio was lean or rich, etc. at the time of the
malfunction.
CHECK:
Drive the vehicle and check if the operation of the speedometer in the combination meter is normal.
HINT:
The vehicle speed sensor is operating normally if the speedometer display is normal.
NG
Check speedometer (See page BE1).
OK
Check for short in harness and connector between terminal SPD of Engine and
ECT ECU connector and body ground.
PREPARATION:
Disconnect the connector of the Engine and ECT ECU.
CHECK:
Check continuity between terminal SPD of the Engine and ECT
ECU connector and body ground.
OK:
No continuity (1M or higher)
ON
SPD
D10027
NG
OK
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DI84
DIAGNOSTICS
Check voltage between terminal SPD of Engine and ECT ECU connector and
body ground.
PREPARATION:
CHECK:
Measure voltage between terminal SPD of Engine and ECT
ECU connector and body ground.
OK:
Voltage: 9 14 V
ON
()
SPD
(+)
D10028
NG
Check for open in harness and connector between J44 junction connector and Engine and
OK
Check for open in harness and connector between J44 junction connector and
combination meter (See page IN30).
NG
OK
Check Engine and ECT ECU (See page IN20).
NG
OK
Check and repair ABS system.
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DI85
DIAGNOSTICS

DI80G01
DTC
P0710
Transmission Fluid Temperature Sensor

Malfunction (ATF Temperature Sensor)
DTC
P0711
Transmission Fluid Temperature Circuit

Range/Performance problem (Europe only)
CIRCUIT DESCRIPTION
The ATF temperature sensor converts fluid temperature into a resistance value which is input into the Engine
and ECT ECU.
DTC No.
Trouble Area
P0710
Either (a) or (b) is detected for 0.5 sec. or more.

(a) Temp. sensor resistance is less than 79 .
(b) After the engine has been operating for 15 minutes or
more, the resistance at the temp. sensor is more than 156 k.
S Open or short in ATF temp. sensor

S ATF temp. sensor
P0711
Both (a) and (b) are detected.

(a) After 12 seconds of the engine start, the temp. of the atmosphere and that of the engine coolant is more than 10C.
(b) After a normal driving for over 20 minutes and 10km, the
ATF temp. is less than 10C.
S Open in ATF temp. sensor

S ATF temp. sensor
WIRING DIAGRAM
Engine and ECT ECU
Automatic Transaxle
O
THO
1
E1
E2
6
E1
8
E14 THO
ATF Temperature
Sensor
O
BR
18 18
IE2 IF2
(RHD) (LHD)
BR
19
E16 E2
D10041
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DI86
DIAGNOSTICS
1
Check ATF temperature sensor.

6
1
D02967
PREPARATION:
(a) Disconnect the solenoid wire connector.
(c) Disconnect all solenoid valve connectors.
(d) Remove the transmission wire harness.
CHECK:
Measure resistance between terminals 1 and 6 of solenoid connector at 25 C (77 F) and 110 C (230 F).
OK:
Resistance (Approx.):
25 C (77 F): 3.5 k
110 C (230 F): 231 263
NG
Replace the ATF temperature sensor (transaxle

wire).
OK
Check harness and connector between ATF temperature sensor and Engine and
NG
OK

(See page IN30).
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DI87
DIAGNOSTICS

DI4ZZ05
DTC
P0750
Shift Solenoid A Malfunction

(SL1 Solenoid Valve) (Europe only)
DTC
P0755
Shift Solenoid B Malfunction

(SL2 Solenoid Valve) (Europe only)
DTC
P0765
Shift Solenoid D Malfunction

(S4 Solenoid Valve) (Europe only)
SYSTEM DESCRIPTION
The Engine and ECT ECU uses signals from the vehicle speed sensor to detect the actual gear position (1st,
2nd, 3rd or O/D gear).
Then the Engine and ECT ECU compares the actual gear with the shift schedule in the Engine and ECT
ECU memory to detect mechanical trouble of the shift solenoid valves and valve body.
DTC No.
P0750
P0755
P0765

During normal driving, the gear required by the ECM does not
match the actual gear
Trouble Area
S SL1/SL2/S4 solenoid valve is stuck open or closed
HINT:
Check the SL1 solenoid valve when DTC P0750/62 is output, check the SL2 solenoid valve when DTC
P0755/63 is output and check S4 solenoid valve when DTC P0765/65 is output.
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DI88
DIAGNOSTICS
1
Check SL1, SL2 or S4 solenoid valve operation.
SL1 and SL2 solenoid valve

1
()
(+)
S4 solenoid valve
(+)
D03445
D03446
D03424 D03423
()
D03724
PREPARATION:
(c) Remove the SL1, SL2 or S4 solenoid valve.
Check Solenoid Resistance:
CHECK:
(a) SL1 or SL2 solenoid valve:
(b) S4 solenoid valve:
Measure resistance between terminal 1 of solenoid connector and solenoid body.
OK:
(a) Resistance: 5.1 5.5
(b) The shift solenoid valve makes operation noise.
Check Solenoid Operation:
CHECK:
Connect the positive (+) lead with an 23W bulb to terminal 1 and the negative () lead to terminal 2 of solenoid
connector, then check the movement of the valve.
Connect the positive (+) lead with an 23W bulb to terminal 1 of solenoid connector and the negative () lead to
the solenoid valve body, then check the movement of the
valve.
OK:
(a) Resistance: 5.1 5.5
(b) The shift solenoid valve makes operation noise.
NG
Replace the SL1, SL2 or S4 solenoid valve.
OK
Check the valve body (See page AX8).
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DI89
DIAGNOSTICS

DI6RY03
DTC
P0753
Shift Solenoid A Electrical Malfunction

DTC
P0758
Shift Solenoid B Electrical Malfunction

DTC
P0768
Shift Solenoid D Electrical Malfunction

(S4 Solenoid Valve)
CIRCUIT DESCRIPTION
Shifting from 1st to O/D is performed in combination with ON and OFF of the SL1 and SL2 solenoid valves
controlled by Engine and ECT ECU. If an open or short circuit occurs in either of the solenoid valves, the
Engine and ECT ECU controls the remaining normal solenoid valve to allow the vehicle to be operated
smoothly (Fail safe function).
DTC No.
P0753
P0758
in the SL1 and SL2 solenoid valves.
(a) When the solenoid is energized, the duty ratio exceed 75
%.
(b) When the solenoid is not energized, the duty ratio is less
than 3 %.
P0768
in the S4 solenoid valve circuit when it changes.
The Engine and ECT ECU records DTC P0768/65 if condition
(a) or (b) is detected.
(a) When the solenoid is energized, the solenoid resistance is
8 or less and is counted.
(b) When the solenoid is not energized, the solenoid resistance
is 100 k or more and is counted.
Trouble Area
S Open or short in SL1/SL2/S4 solenoid valve circuit

S SL1/SL2/S4 solenoid valve
HINT:
Check the SL1 solenoid valve when DTC P0753/62 is output, check the SL2 solenoid valve when DTC
P0758/63 is output and check the S4 solenoid valve when DTC P0768/65 is output.
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DI90
DIAGNOSTICS
Fail safe function:

If either of the shift solenoid valve circuits develops an open or short, the Engine and ECT ECU turns the
other solenoid ON and OFF to shift to the gear positions shown in the table below. The Engine and ECT ECU
also turns the DSL solenoid valve OFF at the same time. If both solenoids are malfunction, hydraulic control
cannot be performed electronically and must be done manually.
Manual shifting as shown in the following table must be done (In the case of a short circuit, the Engine and
ECT ECU stops sending current to the short circuited solenoid).
SL1 SOLENOID MALFUNCTIONING
Driving at 3rd or O/D
Driving at 1st or 2nd
NORMAL
Solenoid Valve
Gear
Solenoid Valve
SL1
SL2
S4
ON
ON
OFF
1st
OFF
ON
OFF
2nd
OFF
OFF OFF
3rd
SL1
SL2
ON
S4
Gear
Solenoid Valve
SL1 SL2 S4
Gear
SL2 SOLENOID
MALFUNCTIONING
Solenoid Valve
Gear
SL1 SL2 S4
ON
OFF
3rd
X
OFF
OFF
3rd
ON
OFF
2nd
OFF
3rd
ON
OFF
2nd
OFF
OFF
3rd
OFF OFF
3rd
3rd
OFF
OFF
3rd
3rd
OFF
ON
O/D
OFF
ON
OFF
OFF OFF
ON
OFF
OFF
OFF
ON
O/D
S4 SOLENOID
MALFUNCTIONING
Solenoid Valve
SL1
SL2
S4
ON
ON
OFF
ON
Gear
OFF
ON
O/D
SL1 AND SL2 SOLENOID

MALFUNCTIONING
Solenoid Valve
Gear
SL2
S4
1st
OFF
3rd
2nd
OFF
3rd
OFF OFF
3rd
OFF
3rd
OFF
3rd
ON
O/D
SL2 AND S4 SOLENOID

MALFUNCTIONING
Solenoid Valve
SL1 SL2 S4
ON
X
X
OFF
Gear
ON
ON
SL1
OFF
SL1 AND S4 SOLENOID MALFUNCTIONING

Driving at 3rd or O/D
Driving at 1st or 2nd
Solenoid Valve
Solenoid Valve
Gear
Gear
SL1 SL2 S4
SL1 SL2 S4
ON
ON
3rd
X
X
2nd
X
X
OFF
ON
3rd
X
ON
X
2nd
X
X
OFF
OFF
X
OFF
3rd
X
X
2nd
X
ON
OFF
X
OFF
X
3rd
X
X
2nd
ON
SL1, SL2 AND S4 SOLENOID

MALFUNCTIONING
Solenoid Valve
Gear
SL1
SL2
S4
3rd
3rd
OFF
3rd
3rd
OFF
3rd
3rd
OFF
3rd
3rd
ON
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DI91
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU
Automatic Transaxle
SL1 Solenoid Valve
SL1+
W
SL1
5
E1
7
E14 SL1+
10
E1
6
E14 SL1
4
E1
17
E14 SL2+
9
E1
E14 SL2
8
E1
26
E14 S4
SL2 Solenoid Valve

SL2+
Y
BR
SL2
16
S4 Solenoid Valve
S4
R
D10189
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DI92
DIAGNOSTICS
1
Measure resistance between terminals of Engine and ECT ECU.
SL1+
SL1
SL2+
SL2
PREPARATION:
CHECK:
(a) Measure resistance between terminals SL1+ and SL1 of
Engine and ECT ECU connector.
(b) Measure resistance between terminals SL2+ and SL2 of
Engine and ECT ECU connector.
(c) Measure resistance between terminal S4 of Engine and
ECT ECU connector and body ground.
OK:
Resistance:
(a) SL1+ SL1: 5.3 0.2
(b) SL2+ SL2: 5.3 0.2
(c) S4 Body ground: 13 2
S4
D10029
OK
Check and replace the Engine and ECT ECU.
NG
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DI93
DIAGNOSTICS
Measure harness and connector between Engine and ECT ECU and automatic
SL1+
SL1+
SL1
SL1
Solenoid Connector
SL2+
SL2+
SL2
PREPARATION:
(a) Disconnect the solenoid connector from the automatic
transaxle.
(b) Disconnect the connector from the Engine and ECT ECU.
CHECK:
(a) Measure the harness and connector between terminal
SL1 + or SL1 of Engine and ECT ECU and terminal SL1+
or SL1 of solenoid connector.
(b) Measure the harness and connector between terminal
SL2 + or SL2 of Engine and ECT ECU and terminal SL2+
or SL2 of solenoid connector.
(c) Measure the harness and connector between terminal S4
of Engine and ECT ECU and terminal S4 of solenoid connector.
OK:
Resistance: 0
SL2
Solenoid Connector
S4
Solenoid Connector
S4
D10030
NG
OK
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DI94
DIAGNOSTICS
Check SL1, SL2 or S4 solenoid valve.
PREPARATION:
(c) Remove the SL1, SL2, or S4 solenoid valve.

CHECK:
Measure resistance between terminal 1 of solenoid connector and solenoid body.
OK:
Resistance: 5.1 5.5
SL1 and SL2 solenoid valve

2
()
(+)
S4 solenoid valve
(+)
D03445
D03446
D03424 D03423
()
D03724

CHECK:
Connect the positive (+) lead with an 23W bulb to terminal 1 and the negative () lead to terminal 2 of solenoid
connector, then check the movement of the valve.
Connect the positive (+) lead with an 23W bulb to terminal 1 of solenoid connector and the negative () lead to
the solenoid valve body, then check the movement of the
valve.
OK:
The shift solenoid valve makes operation noise.
NG
Replace the solenoid valve.
OK
Repair or replace the solenoid wire, harness

and connector between Engine and ECT ECU
and automatic transaxle solenoid connector.
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DI95
DIAGNOSTICS

DI4ZX05
DTC
P0770

(DSL Solenoid Valve) (Europe only)
SYSTEM DESCRIPTION
The Engine and ECT ECU uses the signals from the throttle position sensor, airflow meter and crankshaft
position sensor to monitor the engagement condition of the lockup clutch.
Then the Engine and ECT ECU compares the engagement condition of the lockup clutch with the lockup
schedule in the Engine and ECT ECU memory to detect mechanical trouble of the DSL solenoid valve, valve
body and torque converter.
DTC No.
Trouble Area
Lockup does not occur when driving in the lockup range

(normal driving at 80 km/h [50 mph]), or lockup remains ON
in the lockup OFF range.
P0770
S DSL solenoid valve is stuck open or closed

S Valve body blocked up or stuck
S Lockup clutch
1
Check DSL solenoid valve operation.

()
PREPARATION:
(b) Remove the DSL solenoid valve.
CHECK:
check that the solenoid valve does not leak air.
(b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens.
OK:
(+)
()
(+)
D03447
D03448
D03725
NG
Replace the DSL solenoid valve.
OK
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DI96
DIAGNOSTICS
Check valve body (See page AX8).
NG
OK
Replace the torque converter (See page

AX38).
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DI97
DIAGNOSTICS

DI6RV03
DTC
P0773

CIRCUIT DESCRIPTION
The DSL solenoid valve is turned ON and OFF by signals from the Engine and ECT ECU to control the hydraulic pressure acting on the lockup relay valve, which then controls operation of the lockup clutch.
DTC No.
P0773
Trouble Area
Either (a) or (b) are detected for 1 time.

(a) Solenoid resistance is 8 or less short circuit when solenoid is energized.
(b) Solenoid resistance is 100 k or more open circuit when
solenoid is not energized.
S Open or short in DSL solenoid valve circuit

S DSL solenoid valve
Fail safe function:

If the Engine and ECT ECU detects a malfunction, it turns the DSL solenoid valve OFF.
WIRING DIAGRAM
Engine and ECT ECU
Automatic Transaxle
DSL Solenoid Valve

3
DSL
E1
G
25
P
E14 DSL
D07933
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DI98
DIAGNOSTICS
1
DSL
DSL
PREPARATION:
(a) Disconnect the solenoid connector from the transaxle.
(b) Disconnect the connector from the Engine and ECT ECU.
CHECK:
Measure the harness and connector between terminal DSL of
Engine and ECT ECU and terminal DSL of solenoid connector.
OK:
D10031
NG
OK
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DI99
DIAGNOSTICS
Check shift solenoid valve DSL.
()
()
()
Electrical Check:
PREPARATION:
(c) Disconnect the DSL solenoid valve connector.
(d) Remove the DSL solenoid valve.
CHECK:
(a) Measure resistance between terminal DSL of shift solenoid valve and solenoid body.
(b) Connect positive (+) lead to terminal of solenoid connector, negative () lead to solenoid body.
OK:
(a) Resistance: 11 15
(b) The DSL solenoid valve makes operation noise.
(+)
(+)
Mechanical Check (Except Europe Only):

PREPARATION:
(b) Remove the DSL solenoid valve.
CHECK:
check that the solenoid valve does not leak air.
(b) When battery positive voltage is supplied to the shift solenoid valve, check that the solenoid valve opens.
OK:
(+)
D03420
D03419
D03447
D03448
D08282
NG
Replace the DSL solenoid valve.
OK
Check and replace or repair the solenoid

wire.
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DI100
DIAGNOSTICS

DI80H01
DTC
P1520
Stop Light Switch Signal Malfunction
CIRCUIT DESCRIPTION
The purpose of this circuit is to prevent the engine from stalling, while driving in lockup condition, when
brakes are suddenly applied.
When the brake pedal is operated, this switch sends a signals to Engine and ECT ECU. Then the Engine
and ECT ECU cancels operation of the lockup clutch while braking is in progress.
DTC No.
Trouble Area
S Stop light switch
No stop light switch signal to Engine and ECT ECU during

driving.
P1520
WIRING DIAGRAM
Sedan:

STOP
1
10
IA
IG
WR *5
W *6
Stop Light
Switch
W
21
3F
8
3D
GW
22
E13 STP
8 3C
1 F17
FL
Block
Center J/B
GW
1
Engine and
ECT ECU
GW
GW
ALT
F *1
1 F15
F *1
6
5
ID1 II1
*5 *6
GW
J/C
BG
FL
MAIN
1
2
High D *2 D *2 GW
Mounted GW
2
6
Stop
Stop
Stop Light
Light
Light RH
LH
4 WB
WB 4
A *4
Battery
A *4 A *4
J/C
A *3
WB
WB
A *3
*1: J12 (LHD), J28 (RHD)

*2: J13 (LHD), J29 (RHD)
*3: J10 (LHD), J30 (RHD)
*4: J11 (LHD), J31 (RHD)
*5: LHD
*6: RHD
WB
BL *5
BN *6
BM
F13602
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DI101
DIAGNOSTICS
Lift Back (LHD):

Stop Light
Switch

STOP
1
10
IA
IG
WR
W
1
8
3D
GW
22
E13 STP
8 3C
1 F17
FL
Block
21
3F
GW
2
Engine and
ECT ECU
Center J/B
GW
ALT
6
ID1
GW
GW
D J14 D J14
1 BD1
1 F15
J/C
BG
F J15 F J15
GW
High
FL
Mounted GW
1 Stop
5
3
MAIN
Stop
Stop Light
Light
Light RH
LH
2
3 WB
5 WB
E J15
E J15 B J15
J/C
Battery WB
GW
E J14
WB
WB
E J14 B J14
WB
BO
BQ
BP
Lift Back (RHD):

Stop Light
Switch

STOP
1
10
IA
IG
Center J/B
21
3F
GW
W
2
Engine and
ECT ECU
8
3D
GW
22
E13 STP
FL
Block
1 F17
GW
ALT
GW
E J33 D J32
1 BD1
1 F15
BG
FL
MAIN
Battery
GW E J33 E J33
High
GW
Mounted
1
3
Stop
Stop
Light LH
Light
2
5
WB
BQ
WB
BP
8 3C
5
II1
GW
J/C
GW
5
Stop Light
RH
3
WB
BO
F13603
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DI102
DIAGNOSTICS
Wagon:
WR *1
W *2

STOP
1
10
IA
IG
1 F17
FL
Block
Stop Light
Switch
J16 *1
J34 *2
ALT
Center J/B
GW
6
5
ID1 II1
*1 *2
GW
B
Engine and
ECT ECU
21
3F
8
3D
GW
22
E13 STP
8 3C
GW
J17 *1
J35 *2
1 F15
BG
GW
FL
MAIN
1
2
A
C
C
High
Mounted GW
2 Stop
Stop
Light
Light LH
4
WB
A WB
Battery
A WB
BR
GW
2
Stop Light
RH
4
A WB J17 *1
J35 *2
Junction Connector
A WB
BS
*1: LHD
*2: RHD
F13604
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DI103
DIAGNOSTICS
HINT:
the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the airfuel ratio lean or rich, etc. at the time of the malfunction.
CHECK:
Check if the stop lights go on and off normally when the brake pedal is depressed and released.
NG
Check and repair stop light circuit.
OK
Check STP signal.

ON
Brake Pedal
Released
Brake Pedal
Depressed
ON
STP
()
(+)

PREPARATION:
switch ON.
CHECK:
Read the STP signal on the handheld tester.
OK:
Brake pedal is depressed: STP...ON
Brake pedal is released: STP...OFF
PREPARATION:
(a) Remove the glove compartment door.
CHECK:
Check voltage between terminal STP of the Engine and ECT
ECU and body ground.
OK:
D10032
OK
Brake pedal
Voltage
Depressed
9.0 14 V
Released
Below 1.5 V
Check for intermittent problems.
NG
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DI104
DIAGNOSTICS
Check harness and connector between Engine and ECT ECU and stop light
switch (See page IN20).
NG
OK
Check and replace Engine and

(See page IN20).
ECT ECU
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DI105
DIAGNOSTICS

DI6RW03
DTC
P1725
NT Revolution Sensor Circuit Malfunction

(Input Turbine Speed Sensor)
CIRCUIT DESCRIPTION
This sensor detects the rotation speed of the input turbine. By comparing the input turbine speed signal (NT)
and the counter gear speed sensor signal (NC), the Engine and ECT ECU detects the shift timing of the gears
and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus
performing smooth gear shifting.
DTC No.
P1725

The Engine and ECT ECU detects conditions (a), (b), (c), (d)
and (e) continuity for 5 seconds or more.
(a) Gear change not being performed
(b) Gear position: 2nd, 3rd or O/D gear
(c) Solenoid valves and neutral start switch are normal
(d) T/M input shaft rpm: 300 rpm or less
(e) T/M output shaft rpm: 1,000 rpm or less
Trouble Area
S Open or short in input turbine (NT) speed sensor circuit

S Input turbine (NT) speed sensor
WIRING DIAGRAM
Engine and ECT ECU
2
2
IE2 IF2
(RHD) (LHD)
5
E15 NT+
11
E15 NT
2
T8
Input Turbine
Speed Sensor
1
R
1
1
IE2 IF2
(RHD) (LHD)
D10176
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DI106
DIAGNOSTICS
1
Check resistance between terminals NT+ and NT of Engine and ECT ECU.
NT+
PREPARATION:
CHECK:
Check resistance between terminals NT+ and NT of Engine
and ECT ECU.
OK:
Resistance: 620 60
NT
D10033
OK

(See page IN30).
NG
Check input turbine speed sensor.
Magnet
Q08218
PREPARATION:
Remove the input turbine speed sensor from transaxle.
CHECK:
(a) Measure resistance between terminals 1 and 2 of speed
sensor.
(b) Check voltage between terminals 1 and 2 of the speed
sensor when a magnet is put close to the front end of the
speed sensor then taken away quickly.
OK:
(a) Resistance: 620 60 at 20 C (68 F)
(b) Voltage is generated intermittently.
HINT:
The voltage generated is extremely low.
NG
Replace the input turbine speed sensor.
OK
Check and repair the harness and connector

between Engine and ECT ECU and input turbine speed sensor (See page IN30).
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DI107
DIAGNOSTICS

DI6RX03
DTC
P1730
NC Revolution Sensor Circuit Malfunction

(Counter Gear Speed Sensor)
CIRCUIT DESCRIPTION
This sensor detects the rotation speed of the counter gear. By comparing the counter gear speed signal (NC)
and the input turbine speed sensor signal (NT), the Engine and ECT ECU detects the shift timing of the gears
and appropriately controls the engine torque and hydraulic pressure in response to various conditions, thus
performing smooth gear shifting.
DTC No.
P1730

The Engine and ECT ECU detects conditions (a), (b), (c) and
(d) continuity for 5 secs or more.
(a) IG SW: ON
(b) Neutral start switch: Except P, N range
(c) T/M input shaft rpm: 300 rpm or less
(d) T/M output shaft rpm: 1,000 rpm or more
Trouble Area
S Open or short in counter gear (NC) speed sensor circuit

S Counter gear (NC) speed sensor
WIRING DIAGRAM
Engine and ECT ECU
4
E15 NC+
10
E15 NC
2
C18
Counter Gear
Speed Sensor
1
D07935
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DI108
DIAGNOSTICS
1
Check resistance between terminals NC+ and NC of Engine and ECT ECU.
NC+
PREPARATION:
CHECK:
Check resistance between terminals NC+ and NC of Engine
and ECT ECU.
OK:
Resistance: 620 60
NC
D10034
OK

(See page IN30).
NG
Check counter gear speed sensor.
Magnet
Q08218
PREPARATION:
Remove the counter gear speed sensor from transaxle.
CHECK:
(a) Measure resistance between terminals 1 and 2 of speed
sensor.
(b) Check voltage between terminals 1 and 2 of the speed
sensor when a magnet is put close to the front end of the
speed sensor then taken away quickly.
OK:
(a) Resistance: 620 60 at 20 C (68 F)
(b) Voltage is generated intermittently.
HINT:
The voltage generated is extremely low.
NG
Replace the counter gear speed sensor.
OK
Check and repair the harness and connector

between Engine and ECT ECU and counter
gear speed sensor (See page IN30).
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DI109
DIAGNOSTICS

DI6RZ03
DTC
P1760
Linear Solenoid for Line Pressure Control

Circuit Malfunction (SLT Solenoid Valve)
CIRCUIT DESCRIPTION
Line Pressure Control Pressure
Current Flow to Solenoid D02290
ON
OFF
1 Cycle
The throttle pressure that is applied to the primary regulator

valve (which modulates line pressure) causes the solenoid
valve SLT, under electronic control, to precisely and minutely
modulate and generate line pressure according to the accelerator pedal effort, or engine power output detected.
This reduces the function of line pressure and provides smooth
shifting characteristics.
Upon receiving the throttle valve opening angle signal, Engine
and ECT ECU controls the line pressure by sending a predetermined (*) duty ratio to the solenoid valve, modulating the line
pressure, generating throttle pressure.
(*) Duty Ratio
The duty ratio is the ratio of the period of continuity in one cycle.
For example, if A is the period of continuity in one cycle, and
B is the period of noncontinuity, then
Duty Ratio =
BE4056
DTC No.
P1760

(a) or (b) condition below is detected 1 second or more.
(a) SLT terminal: 0V
(b) SLT terminal: 12V
5 V / Div.
x 100 (%)
Trouble Area
Reference:
Wave form between terminals SLT+ and SLT during engine idling.
GND
1 msec. / Div.
A
A+B
D01875
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DI110
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU
Automatic Transaxle
SLT+
O
2
E1
15
E14 SLT+
7
E1
LW
24
E14 SLT
SLT
Solenoid
Valve
SLT
G
D07928
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DI111
DIAGNOSTICS
1
Check SLT solenoid valve.

2
D03445
D03446
D02968
PREPARATION:
CHECK:
OK:
Resistance: 5.0 5.6 at 20 C (68 F)
CHECK:
Connect positive (+) lead with an 8 10W bulb to terminal 1 of
solenoid connector and negative () lead to terminal 2, then
check the movement of the valve.
OK:
D03729
When battery positive voltage is applied.
Valve moves in
in illustration at right.
direction
When battery positive voltage is cut off.
Valve moves in
in illustration at left.
direction
NG
Replace SLT solenoid valve.
OK
Check harness and connector between SLT solenoid valve and Engine and ECT
NG
OK
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DI112
DIAGNOSTICS

DI4ZS05
DTC
P1780
CIRCUIT DESCRIPTION
The neutral start switch detects the shift lever position and sends signals to the Engine and ECT ECU. The
Engine and ECT ECU receives signals (NSW, R, D 2 and L) from the neutral start switch.
DTC No.
P1780
DTC Detection Condition

When more than one of the following conditions continue for
500 sec. or more.
(a) P, N range input signal is ON.
(b) R range input signal is ON.
(c) N range input signal is ON.
(d) L range input signal is ON.
(e) 2 range input signal is ON.
(h) D range input signal is ON.
When any of following conditions for 500 msec. or more in the
M position.
(a) P, N range input signal is ON.
(b) P range input signal is ON.
(c) N range input signal is ON.
(d) L range input signal is ON.
Trouble Area

S Engine
E i and
d ECT ECU
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DI113
DIAGNOSTICS
WIRING DIAGRAM
Engine and ECT ECU

DL 7
BY
10
E14 D
LL 8
YG
4
E14 L
2L 4
11
E14 2
3
RL
Center J/B
3
3C
RB
RL 2
3
3D
RB
1
E14 R
20
3D
BW
23
E15 NSW
Center J/B
6
7
3E
BW
20 3E
WB
BW
Center J/B
10
3C
10
3A
RL

GAUGE
10
5
IC
IF
Ignition Switch
BY
8 IG1 AM1 5

ST
4
6
IC
IE

WR
1
2
R
ID
ID
3 ST2 AM2 4
BW
Engine Room J/B
WR
3 2A
MAIN
6
2A
1
2D
Starter Relay
To Starter
J9*1 J20*2
Junction Connector
IJ *1
II *2
FL
MAIN
AM2
6
2C
2H
W
BG BG
1
F15
FL
Block
ALT
2 *1
1 *2
F17

W
2
IA
AM1
1
3
IC
Battery
*1: LHD
*2: RHD
D10179
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DI114
DIAGNOSTICS
1
Read PNP, REVERSE, 2ND DRIVE and LOW signals.

PREPARATION:
switch ON.
CHECK:
Shift lever into the P, R, N, D, 2 and L positions, and read the
PNP, REVERSE, 2ND DRIVE and LOW signals on the hand
held tester.
OK:
ON
Signal
2ND OFF ON
LOW OFF ON
DRIVE OFF ON
REVERSE OFF ON
P, N
PNP OFF ON

PREPARATION:
CHECK:
Measure voltage between terminals P. R. N. D. 2 and L of Engine and ECT ECU and body ground when the shift lever is
shifted to the following positions.
OK:
R
D
NSW
Shift range
2
D10035
Shift range
Tester connection
Specified value
P, R
NSW Body ground
Battery positive voltage
R Body ground
*Battery positive voltage
D Body ground
2 Body ground
L Body ground
HINT:
*: The voltage will drop slightly due to lighting up of the back up
light.
OK

(See page IN30).
NG
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DI115
DIAGNOSTICS
Check neutral start switch.

PREPARATION:
(b) Remove the neutral start switch.
CHECK:
Check continuity between each terminal shown below when the
shift lever is moved to each position.
5 4 32 1
9 8 7 6
Shift range
D06561
Terminal No. to continuity
69
23
69
37
34
38
OK:
NG
Replace the neutral start switch.
OK
Repair or replace harness and connector between battery and neutral start switch, neutral start switch and Engine and ECT ECU (See page IN30).
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DI116
DIAGNOSTICS

DI6SY03
O/D Main Switch & O/D OFF Indicator Light Circuit

CIRCUIT DESCRIPTION
The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out.
If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the Engine and ECT ECU
prohibits shifting overdrive.
WIRING DIAGRAM
O/D OFF Indicator Light
(Combination Meter)
9
8
C11
C11
Engine and ECT ECU
BO
Center J/B
10
3F
11
E13 OD2
O/D Main Switch
10
3A
RL
Center J/B

5
IC
GAUGE
13
3A
10
IF
BY
WB
13
3C
WB
Ignition Switch
8
5
AM1
IG1
IE 4 Instrument
Panel
J/B
W
W
2
IA
FL
2 *1 Block
1 *2 ALT
F17
AM1
3
IC
IC 1
WB
FL
1
MAIN
BG
F15
A
J1 (LHD)
J27 (RHD)
Junction Connector
*1: LHD
*2: RHD
Battery
II (LHD)
IJ (RHD)
D10177
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DI117
DIAGNOSTICS
O/D OFF indicator light does not light up
1

PREPARATION:
CHECK:
Check continuity between terminals 5 and 6 of O/D main switch
connector.
OK:
O/D main switch
Q08078
NG
Resistance
ON
(open)
OFF
0 (continuity)
OK
Check and replace combination meter (See page BE1).
NG
Replace the combination meter.
OK
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DI118
DIAGNOSTICS
Check OVERDRIVE CUT SW2 signal.

PREPARATION:
(a) Connect a handheld tester to the DLC3.
switch ON.
CHECK:
Read the OVERDRIVE CUT SW2 signal on the handheld tester.
OK:
ON
O/D main switch condition
OVERDRIVE CUT SW2 signal
Pushed in
OFF
Pushed out
ON

PREPARATION:
CHECK:
Check voltage between terminal OD2 of Engine and ECT ECU
and body ground.
OK:
OD2
D10036
OK
O/D main switch
Voltage
OFF
Below 1.0 V
ON
10 14 V

(See page IN30).
NG
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DI119
DIAGNOSTICS
Check harness and connector between O/D OFF indicator light and Engine and
PREPARATION:
Disconnect the connector of Engine and ECT ECU and the connector of the combination meter.
CHECK:
Measure the continuity between the connector of Engine and ECT ECU and the connector of the combination meter.
OK:
Continuity
NG
OK
Repair or replace the wire harness or connectors between the connector of Engine
and ECT ECU and body Ground.
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DI120
DIAGNOSTICS
O/D OFF indicator light remains ON

1

PREPARATION:
CHECK:
Check continuity between terminals 1 and 2 of O/D main switch
connector.
OK:
Q08078
NG
O/D main switch
Resistance
ON
(open)
OFF
0 (continuity)
OK
Check harness and connector between O/D OFF indicator light and O/D main
switch, O/D OFF indicator light and Engine and ECT ECU (See page IN30).
NG
OK

(See page IN20).
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DI121
DIAGNOSTICS

DI33604
Pattern Select Switch Circuit

CIRCUIT DESCRIPTION
The Engine & ECT ECU memory contains the shift programs for the NORMAL, POWER and SNOW (w/
SNOW mode) patterns, 2 range, L range and the lockup patterns. By following the programs corresponding
to the signals from the pattern select switch, the neutral start switch and other various sensors, the Engine
& ECT ECT switches the solenoid valves ON and OFF, and controls the transaxle gear change and the lock
up clutch operation.
WIRING DIAGRAM
NORM 5
3
E5
E5
SNOW
2
E5
PWR
RL
Engine and ECT ECU

19
E14 SNWI
PB
Center J/B
15
15
3D
3B
9
E14 PWR
15 3F
P
BO
3F 10
10 3B
3F 1
RL
22
7
RY E13 SNWL
C10
22
C11
Center J/B
10 3A
Combination Meter
9
C11
ECT SNOW
14
WB
C10
24
C10
ECT PWR
BO

GAUGE
10
IF
5
IC
Ignition Switch
BY 8
WB
5
IG1
AM1
J1*1
J27*2
Junction
Connector
W
3
IC
AM1
2
2
IA
1
WB
C10
FL
Block
2 *1
1 *2
ALT
F17
1
F15
BG
FL
MAIN
Battery
II*1
IJ*2
*1: LHD
*2: RHD
D10184
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DI122
DIAGNOSTICS
1
Check PATTERN SEL SW signal.

PREPARATION:
switch ON.
CHECK:
Read the PATTERN SEL SW signal on the handheld tester.
OK:
ON
Pattern select switch
PATTERN SEL SW signal
POWER
ON
NORM
OFF
SNOW
OFF

PREPARATION:
CHECK:
Measure voltage between terminal each of PWR, SNWI of Engine & ECT ECU and body ground when the pattern select
switch is set to the PWR (POWER), NORM (NORMAL) or
SNOW (SNOW) position.
OK:
PWR
SNWI
D10188
Switch position
Tester connection
Specified condition
PWR Body ground
9 14 V
SNWI Body ground
Below 1.5 V
PWR Body ground
Below 1.5 V
SNWI Body ground
Below 1.5 V
PWR Body ground
Below 1.5 V
SNWI Body ground
9 14 V
PWR
NORM
SNOW
HINT:
The Engine & ECT ECU uses the normal pattern signal if the
PWR and SNWI signals are not input.
OK

symptom problems table (See page DI79).
NG
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DI123
DIAGNOSTICS
Check pattern select switch

PREPARATION:
Disconnect the pattern select switch connector.
CHECK:
Check continuity between terminals 2 and 3 (PWR, NORM), 3
and 5 (SNOW) of pattern select switch connector when the select switch is set to PWR, NORM or SNOW position.
OK:
2
3
Switch position
Tester connection
Specified condition
PWR
23
Continuity
NORM
2 3, 3 5
No continuity
SNOW
35
Continuity
D10186
NG
Replace the pattern select switch.
OK
Check harness and connector between battery and pattern select switch, pattern
select switch and Engine & ECT ECU (See page IN30).
NG
OK
Check and replace the Engine & ECT ECU

(See page IN30).
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DI124
DIAGNOSTICS

DI70303
Kickdown Switch Circuit (LHD)

CIRCUIT DESCRIPTION
The kickdown switch is turned ON when the accelerator pedal is depressed beyond the full throttle opening
and sends signals to Engine and ECT ECU.
When the kickdown switch is turned ON, the Engine and ECT ECU controls gear shifting according to the
programmed shift diagrams.
If a short circuit develops in the kickdown switch, the Engine and ECT ECU disregards the kickdown signals and controls shifting at the normal shift points.
WIRING DIAGRAM
Engine and ECT ECU
Kickdown
Switch
WB
17
E13 KD

4
IE
1
IC
WB
J1 (LHD)
J27 (RHD)
Junction
connector
II (LHD)
IJ (RHD)
D10178
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DI125
DIAGNOSTICS
1
Check KICK DOWN SW signal.

PREPARATION:
switch ON.
CHECK:
Read the KICK DOWN SW signal on the handheld tester.
OK:
Accelerator Pedal
ON
KD
KICK DOWN
SW signal
ON
OFF

PREPARATION:
CHECK:
Measure voltage between terminal KD of Engine and ECT ECU
connector and body ground when accelerator pedal is fully depressed or not.
OK:
D10037
Accelerator Pedal
Voltage
Below 1 V
10 14 V
OK

NG
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DI126
DIAGNOSTICS
Check kickdown switch.

PREPARATION:
Disconnect the kickdown switch connector.
CHECK:
Check continuity at each terminal of kickdown switch connector.
OK:
D07967
NG
Kickdown Switch
Specified continuity
ON
Continuity
OFF
No continuity
Replace kickdown switch.
OK
Check harness and connector between Engine and ECT ECU and kickdown
switch, kickdown switch and body ground (See page IN30).
NG
OK

page IN30).
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DIAGNOSTICS

DI127
ANTILOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE

FORCE DISTRIBUTION (EBD)
DI7YR01

Troubleshoot in accordance with the procedure on the following pages.
1

P. DI128
Check and Clear DTC (Precheck)

P. DI129
Items inside
are titles of pages in this manual,
with the page number in the bottom portion. See
the pages for detailed explanations.
Symptom
does not occur
3
Symptom Simulation
PDI127.

P. DI135
Symptom
occurs
Normal code
DTC Check
P. DI129
Malfunction code
DTC Chart
P. DI132
Circuit Inspection
9
Sensor Check
P. DI136 DI166
Check for Fluid Leakage

P. DI168
10
11
Repair
Confirmation Test
End
Fail safe function:
When a failure occurs in the ABS system, the ABS warning light is lit and the ABS operation is prohibited. In addition
to this, when the failure which disables the EBD operation occurs, the brake warning light is lit as well and EBD
operation is prohibited.
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DI128
DIAGNOSTICS

DI7YS01

ABS Check Sheet
Inspectors
:
Name
Registration No.
Registration Year
Customers Name
Frame No.
Date Vehicle
Brought In
km
miles
Odometer Reading
Frequency Problem Occurs
Continuously
/
Intermittently (
times a day)
ABS does not operate.

ABS does not operate intermittently.
Symptoms
ABS Warning Light

Abnormal
Remains ON
Does not Light Up
Brake Warning
Light Abnormal
Remains ON
Does not Light Up
1st Time
Normal Code
Malfunction Code (Code
2nd Time
Normal Code
DTC Check
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DIAGNOSTICS

DI129
DI7YT01
PRECHECK
1.
(a)
(b)
DIAGNOSIS SYSTEM
Release the parking brake lever.
Check the indicator.
When the ignition switch is turned ON, check that the ABS
warning light and brake warning light goes on for 3 seconds.
HINT:
F12747
S
S
(c)
Tc
When the parking brake is applied or the level of the brake

fluid is low, the brake warning light is lit.
If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit or brake
warning light circuit (See page DI159, DI161).
Check the DTC

(1) Using SST, connect terminals Tc and CG of DLC3.
SST 09843 18040
(2) Turn the ignition switch ON.
(3) Read the DTC from the ABS warning light on the
combination meter.
HINT:
S
DLC3
CG
F04969
If no code appears, inspect the diagnostic circuit or ABS

warning light circuit (See page DI164 or DI159).
As an example, the blinking patterns for normal code and

codes 11 and 21 are shown on the left.
(4) Codes are explained in the code table on page
DI132.
(5) After completing the check, disconnect terminals Tc
and CG, and turn off the display.
If 2 or more malfunctions are indicated at the same time the lowest numbered DTC will be displayed 1st.
Normal Code
0.25 secs.
0.5 secs.
0.25 secs.
ON
OFF
Code 11 and 21
0.5 secs.
1.5 secs.
4 secs.
0.5 secs.
2.5 secs.
ON
OFF
Code 11
Code 21
F00103
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DI130
DIAGNOSTICS
(d)
BR3890

Clear the DTC.

SST 09843 18040
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of DLC3.
SST 09843 18040
HINT:
Cancellation cannot be done by removing the battery cable or
ECUIG fuse.
2.
(a)
Ts
DLC3
CG
SPEED SENSOR SIGNAL

Check the speed sensor signal.
(1) When the ignition switch is turned ON, check that
the ABS warning light goes on for 3 seconds.
(3) Using SST, connect terminals Ts and CG of DLC3.
SST 09843 18040
F04969
(5)
0.13 secs.
0.12 secs.
ON
OFF
BR3904
Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI159).
(6) Drive vehicle straight forward.
Drive vehicle at 45 55 km/h (28 34 mph) for several seconds.
HINT:
If the brake is applied during the check, the check routine must
be started again.
(7) Stop the vehicle.
(9) Disconnect the SST from terminals Ts and CG, and
connect the SST to terminals Tc and CG of DLC3.
SST 09843 18040
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DIAGNOSTICS

DI131
(11) Read the number of blinks of the ABS warning light.

HINT:
S
S
S
See the list of DTC shown below.

If every sensor is normal, a normal code is output (A cycle
of 0.25 secs. ON and 0.25 secs. OFF is repeated).
If 2 or more malfunctions are indicated at the same time,
the lowest numbered code will be displayed 1st.
Malfunction Code (Example Codes 72, 76)

7
2
ON
OFF
1.5 secs.
0.5 secs.
0.5 secs.
0.5 secs.
2.5 secs.
4 secs.
0.5 secs.
Repeat
BR3893
(12) After doing the check, disconnect the SST from terminals Tc and CG of DLC3 and turn ignition switch
OFF.
SST 09843 18040
DTC of the speed sensor check function:
Code No.
Diagnosis
Trouble Area
71
Low output voltage of right front speed sensor
S Right front speed sensor

S Sensor installation
S Right front speed sensor rotor
72
Low output voltage of left front speed sensor
S Left front speed sensor

S Left front speed sensor rotor
73
Low output voltage of right rear speed sensor
S Right rear speed sensor

S Right rear speed sensor rotor
74
Low output voltage of left rear speed sensor
S Left rear speed sensor

S Left rear speed sensor rotor
75
Abnormal change in output voltage of right front speed sensor
Right front speed sensor rotor
76
Abnormal change in output voltage of left front speed

sensor
Left front speed sensor rotor
77
Abnormal change in output voltage of right rear speed

sensor
Right rear speed sensor rotor
78
Abnormal change in output voltage of left rear speed sensor
Left rear speed sensor rotor
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DI132
DIAGNOSTICS

DI7YU01

HINT:
S
S
Using SST 09843 18040, connect the terminals Tc and CG.

If a malfunction code is displayed during the DTC check, check the circuit listed for that code. For details of each code, turn to the page referred to under the See page for respective DTC No. in the
DTC chart.
DTC No.
(See Page)
Detection Item
Trouble Area
ABS solenoid valve relay faulty
S ABS solenoid valve relay

S Valve supply voltage
S ECU
13
(DI138)
ABS pump motor faulty
S ABS motor relay

S Pump motor voltage
S Pump motor lead disconnected
S ECU
21
(DI140)
Right front solenoid valves faulty
ABS actuator (right front inlet or outlet solenoid valve)
22
(DI140)
Left front solenoid valves faulty
ABS actuator (left front inlet or outlet solenoid valve)
23
(DI140)
Right rear solenoid valves faulty
ABS actuator (right rear inlet or outlet solenoid valve)
24
(DI140)
Left rear solenoid valves faulty
ABS actuator (left rear inlet or outlet solenoid valve)
31
(DI142)
Right front wheel speed sensor signal malfunction
32
(DI142)
Left front wheel speed sensor signal malfunction
33
(DI142)
Right rear wheel speed sensor signal malfunction
34
(DI142)
Left rear wheel speed sensor signal malfunction
35
(DI142)
Open circuit in right front wheel speed sensor circuit
36
(DI142)
Open circuit in left front wheel speed sensor circuit
37
(DI147)
Speed sensor rotor is wrong number of teeth on one of the 4

wheels
38
(DI142)
Open circuit in right rear wheel speed sensor circuit
39
(DI142)
Open circuit in left rear wheel speed sensor circuit
11
(DI136)
S Right front, left front, right rear and left rear speed sensor
S Each sspeed
eed sensor circuit
S ECU
S Right front, left front speed sensor

S Each
E h speed
d sensor circuit
i it
S ECU
S Speed sensor
S Sensor rotor
S ECU
S Right rear, left rear speed sensor
S Each
E h speed
d sensor circuit
i it
S ECU
41
(DI149)
Low battery voltage
S Battery
S IC regulator
S Power source circuit
S ECU
58
(DI153)
Open circuit in stop light switch circuit
S Stop light switch

S Stop light switch circuit
S ECU
62
(DI157)
Malfunction in ECU
ECU
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DIAGNOSTICS

DI133
DI7YV01
PARTS LOCATION
ABS Warning Light

Brake Warning Light
Rear Speed Senser
ABS Actuator
(w/ ECU, Relay)
Front Speed Sensor
Rear Speed Senser

Rotor
Front Speed Sensor
Rotor
DLC3
F04286
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DI134
DIAGNOSTICS

DI7YW01
TERMINALS OF ECU
A6
F10161
Wiring Color
Condition
STD Voltage (V)
+B (A6 17, 18) GND (A6

16, 19)
B WB
IG1(A6 15) GND (A6 16,

19)
BR WB
WA (A6 20) GND (A6 16,

19)
P L WB
PL
W B
STP (A6 14) GND (A6 16,

19)
G W WB
GW
W B
Tc (A6 12) GND (A6 16,

19)
LGR WB
IG switch ON
5.7 8.1
Ts (A6 11) GND (A6 16,

19)
RB WB
IG switch ON
5.7 8.1
WR*1 B
IG switch ON,
slowly turn right front wheel
AC generation
IG switch ON,
slowly turn left front wheel
AC generation
IG switch ON,
slowly turn right rear wheel
AC generation
IG switch ON,
slowly turn left rear wheel
AC generation
FR (A6 5) FR
FR+
FR (A6 4)
W*2
R LW
FL+ (A6 7) FL (A6 6)
RR (A6 2) RR
RR+
RR (A6 1)
P LR*1
P L*2
Y BR
RL+ (A6 9) RL (A6 8)

SP1 (A6 10) GND (A6 16,
19)
L WB
PKB (A6 13) GND (A6 16,

19)
R W WB
RW
W B
PN (A6 23) GND (A6 16,

19)
B W WB
BW
W B
EBDW (A6 21) GND

(A6 16, 19)
*1:
*2:
R W WB
RW
W B
Constant
10 14
IG switch ON
10 14
IG switch ON, ABS warning light ON
10 14
IG switch ON, ABS warning light OFF
Below 2.6
Stop light switch OFF
Below 1.5
Stop light switch ON
5 14
Vehicle driveing at about 20 km/h (12 mph)
Pulse generation
IG switch ON, parking brake switch ON
Below 2.6
IG switch ON, parking brake switch OFF
10 14
IG switch ON, shift lever P or N range
10 14
IG switch ON, except shift lever P or N range
Below 1.6
IG switch ON, brake warning light OFF
Below 2.6
IG switch ON, brake warning light ON
10 14
LHD
RHD
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DIAGNOSTICS

DI135
DI7YX01

If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each
problem symptom in the order given in the table below and proceed to the relevant troubleshooting page.
Symptoms
Inspection Circuit
See page
Only when 1.to 4. are all normal and the problem is still occurring, replace the
ABS ECU.
1. Check the DTC reconfirming that the normal code is output.
2. Power source circuit
3. Speed sensor circuit
4. Check the hydraulic circuit for leakage.
DI129
DI149
DI142
DI168
ABS does not operate

intermittently.
Only when 1. 4. are all normal and the problem is still occurring, replace the
ABS ECU.
1. Check the DTC reconfirming that the normal code is output.
4. Check the hydraulic circuit for leakage.
DI129
DI142
DI153
DI168
ABS warning light

abnormal.
1. ABS warning light circuit

2. ABS ECU
DI159
Brake warning light

abnormal.
1. Brake warning light circuit

2. ABS ECU
DI161
DTC check cannot be done.
Only when 1. and 2. are all normal and the problem is still occurring, replace the
ABS ECU.
2. Tc terminal circuit
Speed sensor signal check

cannot be done.
1. Ts terminal circuit
2. ABS ECU
DI159
DI164
DI166
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DI136
DIAGNOSTICS

DI7YY01
CIRCUIT INSPECTION
DTC
11
ABS Solenoid Valve Relay Circuit
CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is
OK, the relay goes on.
DTC No.
11
Detection of any conditions from 1. through 3.:

3. 3 or more solenoid valves are detected faulty in response and at the same time valve supply voltage is
detected faulty.
4. Solenoid valve relay will not be switched OFF.
5. Valve relay is stuck in spite of its high valve relay supply
voltage.
Trouble Area
S ABS solenoid valve relay

S Valve supply voltage
S ECU
WIRING DIAGRAM
B
B
(*4) (*2)
2 2
1
18 A6 17 A6
+B
+B
Valve Relay
ABS
60A
ALT
140A*2
1 F15 120A*3
B (*2)
100A*1
BG(*3 )
W(*1)
FL Main
3.0w*2,*3
2.0L*1
Battery
*1: 1ZZFF,3ZZFE,3SFE
*2: 1CDFTV
*3: 1AZFSE
*4: Except 1CDFTV
*5: LHD
*6: RHD
EA1 EC1
1 F20
Fusible
Link
Block
EA1 EC1
Motor Relay
ECU
GND
GND
A6 19
WB
J9 (*5)
WB
J27 (*6) A
WB A
J1 (*5)
J/C
J20 (*6)
J/C
IJ
16 WB
A6
Engine Room J/B
2B 8
1
WB
2F
2F 3
WB
EB
II
WB
WB
EA
F13402
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DIAGNOSTICS

DI137
1
Check voltage between terminals A6 17, 18 and A6 16, 19 of ABS actuator

connector.
PREPARATION:
Disconnect the ABS actuator connector.
CHECK:
Measure the voltage between terminals A6 17, 18 and A6
16, 19 of ABS actuator harness side connector.
OK:
Voltage: 10 14 V
LOCK
A6
18 17
()
16
(+)
19
F00064
NG
Check and replace fuses.

Check and repair harness or connector.
OK
If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective.
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DI138
DIAGNOSTICS

DI7YZ01
DTC
13
Pump Motor Circuit
CIRCUIT DESCRIPTION
The ABS motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches
the ABS motor relay ON and operates the ABS pump motor.
DTC No.
Trouble Area
13

1. After actuating the motor relay, voltage will not be supplied to the pump motor within 0.4 secs.
2. Although the voltage supplied to the pump motor is in a
high level, motor relay will not actuate for 2.5 secs, or
more.
3. The voltage supplied to the pump motor keeps low level
for louger than 0.4 secs. and the pump repeats activating for 7 secs. 3times maximally. After the last activation,
the pump motor has been gone dead because of short
circuit.
S ABS motor relay

S Pump motor voltage
S Pump motor lead disconnected
S ECU
WIRING DIAGRAM
B
B
(*4) (*2)
2 2
1
18 A6 17 A6
+B
+B
Valve Relay
ABS
60A
ALT
140A*2
1 F15 120A*3
B (*2)
100A*1
BG(*3 )
W(*1)
FL Main
3.0w*2,*3
2.0L*1
Battery
*2: 1CDFTV
*3: 1AZFSE
*4: Except 1CDFTV
*5: LHD
*6: RHD
EA1 EC1
1 F20
Fusible
Link
Block
EA1 EC1
Motor Relay
ECU
GND
GND
A6 19
WB
J9 (*5)
WB
J27 (*6) A
WB A
J1 (*5)
J/C
J20 (*6)
J/C
IJ
16 WB
A6
Engine Room J/B
2B 8
1
WB
2F
2F 3
WB
EB
II
WB
WB
EA
F13402
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DIAGNOSTICS

DI139
1
Check voltage between terminals A6 17, 18 and A6 16, 19 of ABS actuator

connector.
PREPARATION:
Disconnect the ABS actuator connector.
CHECK:
Measure the voltage between terminals A6 17, 18 and A6
16, 19 of ABS actuator harness side connector.
OK:
Voltage: 10 14 V
LOCK
A6
19
17
18
()
16
(+)
F00064
NG

Check and repair harness or connector.
OK
If the same code is still output after the DTC is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective.
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DI140
DIAGNOSTICS

DI7Z001
DTC
21, 22, 23, 24
ABS Solenoid Valve Circuit
CIRCUIT 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.
21, 22, 23, 24
Solenoid valve signal does not match for the check result.
Trouble Area
Each solenoid valve
WIRING DIAGRAM
B
B
(*4) (*2)
2 2
1
18 A6 17 A6
+B
+B
Valve Relay
ABS
60A
ALT
140A*2
1 F15 120A*3
B (*2)
100A*1
BG(*3 )
W(*1)
FL Main
3.0w*2,*3
2.0L*1
Battery
*2: 1CDFTV
*3: 1AZFSE
*4: Except 1CDFTV
*5: LHD
*6: RHD
EA1 EC1
1 F20
Fusible
Link
Block
EA1 EC1
Motor Relay
ECU
GND
GND
A6 19
WB
J9 (*5)
WB
J27 (*6) A
WB A
J1 (*5)
J/C
J20 (*6)
J/C
IJ
16
WB
A6
Engine Room J/B
2B 8
1
WB
2F
2F 3
WB
EB
II
WB
WB
EA
F13402
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DIAGNOSTICS

1
Check the DTC once more.
PREPARATION:
(a) Clear the DTC (See page DI129).
(b) Turn the ignition switch OFF.
CHECK:
Turn the ignition switch ON, and check if the same DTC is stored in the memory.
NO
No problem.
YES
Replace ABS ECU.
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DI141
DI142
DIAGNOSTICS

DI7Z101
DTC
31, 32, 33, 34, 35, 36, 38, 39
Speed Sensor Circuit
CIRCUIT DESCRIPTION
The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control
the ABS system. The front and rear rotors each have 48 serrations.
When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage.
Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU
to detect the speed of each wheel.
Speed Sensor
S Magnet
N
Rotor
Coil
To ECU
Low Speed
High Speed
+V
BR3583
BR3582
F00010
DTC No.
Trouble Area
31, 32, 33, 34
Detection of any of conditions from 1. through 3.:

1. Vehicle speed is more than 40 km/h (25 mph), pulses
are not input for 0.01 secs.
2. After the initial start or restart and when the vehicle
speed has reached 12 km/h (7 mph), the wheel with 0
km/h (0 mph) of wheel speed was detected.
speed has reached 70 km/h (44 mph), front wheel with 0
km/h (0 mph) of wheel speed was detected.
4. In case that the vehicle equipped with the temporaly tire
is driven with high speed but without low pressure in that
temporaly tire.
S Right front, left front, right rear, left rear speed sensor
S Each speed sensor circuit
S ECU
S Tire pressure
35, 36, 38, 39
Detecting abnormality in the resistance value of each speed

sensor.
S ECU
HINT:
S
S
S
S
DTC
DTC
DTC
DTC
Nos.
Nos.
Nos.
Nos.
31
32
33
34
and
and
and
and
35 are for the right front speed sensor.

36 are for the left front speed sensor.
38 are for the right rear speed sensor.
39 are for the left rear speed sensor.
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DIAGNOSTICS

DI143
WIRING DIAGRAM
ABS ECU with
Actuator
Left Front
Speed Sensor
1
2
Right Front
Speed Sensor
1 W
(Shielded)
(*1)
2
B (*1)
R (*2)
7
A6
FL+
LW
6
A6
FL
W (*1)
WR (*2) 5
A6
FR+
4
A6
FR
1
IH2
(Shielded)
2
IH2
3
IH2
(*1)
B
WB
Left Rear
Speed Sensor
1 Y
(Shielded)
9
9
IC1 ID1
B (*1)
BR (*2)
WB
(*2)
BR
II1
(*1)
8 7
II1 II1
(Shielded)
9
II1
2
L (*1)
V (*2)
9
A6 RL+
8
A6
(Shielded)
(*1)
8
II1
(*2)
L (*1)
LR (*2)
WB
RL
2
A6 RR+
A
A
J1 (*2), J20(*1)
J/C
(*1)
Y
10 10
IC1 ID1
(*1) 11
ID1
2)
(*
7
Right Rear
Speed Sensor
1 P
(Shielded)
1
A6 RR
19
A6
GND
A WB
J9 (*2), J27(*1)
J/C
IJ
II
*1 RHD
*2 LHD
F13403
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DI144
DIAGNOSTICS

1
Check speed sensor.
1
2
R14205
R14213
Front
PREPARATION:
(a) Remove the front fender liner.
(b) Disconnect the speed sensor connector.
CHECK:
Measure resistance between terminals 1 and 2 of speed sensor
connector.
OK:
Resistance: 0.6 2.5 k (1.6 0.2 k at 20 C)
CHECK:
connector and body ground.
OK:
Rear
PREPARATION:
(a) Remove the seat cushion and side seatback.
CHECK:
connector.
OK:
CHECK:
connector and body ground.
OK:
NG
Replace speed sensor.
NOTICE:
Check the speed sensor signal last (See page DI129).
OK
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DIAGNOSTICS

DI145
Check for open and short circuit in harness and connector between each speed
sensor and ECU (See page IN30).
NG
OK
Check speed sensor installation.

CHECK:
Check the speed sensor installation.
OK:
The installation bolt is tightened properly and there is
no clearance between the sensor and front steering
knuckle or rear axle carrier.
OK
NG
BR3795
NG
NOTICE:
OK
Check speed sensor and sensor rotor serrations.

Normal Signal Waveform
GND
2 m/s / Division
1 V / Division
REFERENCE: INSPECTION USING OSCILLOSCOPE

PREPARATION:
(a) Remove the ABS ECU.
(b) Connect the oscilloscope to the terminals FR+, FL+, RR+
or RL+ and GND of the ABS ECU.
CHECK:
Drive the vehicle at about 30 km/h (19 mph), and check the signal waveform.
W04200
OK
Check and replace ABS ECU.
NG
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DI146
DIAGNOSTICS

Check sensor rotor and sensor tip.
R00948
R00947
Front
PREPARATION:
Remove the front drive shaft (See page SA3).
CHECK:
Check the sensor rotor serrations.
OK:
No scratches or missing teeth or foreign objects.
PREPARATION:
Remove the front speed sensor (See Pub. No. RM599E on
page BR41).
CHECK:
Check the sensor tip.
OK:
No scratches or foreign objects on the sensor tip.
Rear
PREPARATION:
Remove the axle hub (See Pub. No. RM599E on page SA10).
CHECK:
OK:
No scratches or missing teeth or foreign objects.
PREPARATION:
Remove the rear speed sensor (See Pub. No. RM599E on
page BR44).
CHECK:
OK:
NG
Replace sensor rotor or speed sensor.
NOTICE:
OK
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DIAGNOSTICS

DI147
DI7Z201
DTC
37
Speed Sensor Rotor Faulty
CIRCUIT DESCRIPTION
DTC No.
Trouble Area
37

1. Occurrence of differential to some degree in the wheel
speed between the front and rear wheels of either left or
right side of the vehicle and the front left and right
wheels. (Detection of differential in mini tire size, spinning wheel and decelerating wheel.)
2. Continuous ABS control for 60 secs. or more.
3. Interference on 1 or more wheels for 20 secs. with the
brake pedal depressed, or for 5 secs. when the brake
pedal is not depressed.
4. In case that the vehicle equipped with the temporaly tire
is driven with high speed but without low pressure in that
temporaly tire.
S Speed sensor
S Sensor rotor
S ECU
S Tire pressure
1
Check sensor rotor (See page DI142).
NG
Replace sensor rotor.
OK
Check speed sensor (See page DI142).
NG
OK
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DI148
DIAGNOSTICS

Check for open or short circuit in harness and connector between speed sensor
and ECU (See page IN30).
NG
Repair or replace harness and connector.
OK
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DIAGNOSTICS
DI149

DI7Z301
DTC
41
Power Source Circuit
CIRCUIT DESCRIPTION
This circuit is the power source for the ECU, hence the actuators.
DTC No.
Trouble Area
When the vehicle speed is at aprox. 6 km/h (4 mph), low

battery voltage is less than 9.4 V at the time of nonoperation of ABS control or less than 8.8 V at the time of operation of ABS control, and high battery voltage is more than
17.4 V.
41
S Battery
S IC regulator
S ECU
Fail safe function:

If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid valve relay and
prohibits ABS control.
WIRING DIAGRAM
B
B
(*4) (*2)
2 2
1
BR 18
3D
EA1 EC1
18
3A

BR
18 A6 17 A6 A6 15
+B
+B IG1
Valve Relay
1 F20
ABS
60A
Fusible
Link
Block
Center J/B
EA1 EC1
Motor Relay
ALT
9
IE
ECUIG
*2: 1CDFTV
*3: 1AZFSE
*4: Except 1CDFTV
*5: LHD
*6: RHD
ECU
1 F15
B (*2)
BG(*3 )
W(*1)
Battery
FL Main
3.0w*2,*3
2.0L*1
GND
GND
A6 19
WB
J9 (*5)
WB
J27 (*6) A
WB A
J1 (*5)
J/C
J20 (*6)
J/C
IJ
II
16
WB
A6
Engine Room J/B

2B 8
1
2F
WB
2F 3
WB
EB
WB
WB
EA
F13404
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DI150
DIAGNOSTICS

1
Check battery voltage.
OK:
Voltage: 10 14 V
NG

Check and repair the charging system.
OK
Check voltage between terminals IG1 and GND of ABS actuator connector.
PREPARATION:
Disconnect ABS actuator connector.
CHECK:
(a) Turn the ignition switch ON.
(b) Measure voltage between terminals IG1 and GND of ABS
actuator harness side connector.
OK:
Voltage: 10 14 V
ON
IG1
GND
(+)
()
F00067
NG

OK
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DIAGNOSTICS

DI151
Check continuity between terminals GND of ABS actuator connector and body
ground.
CHECK:
Measure resistance between terminals GND of ABS actuator
harness side connector and body ground.
OK:
LOCK
()
(+)
GND
F00068
NG
OK
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DI152
DIAGNOSTICS

Check ECUIG fuse.
ECUIG
PREPARATION:
Remove ECUIG fuse from instrument panel J/B.
CHECK:
Check continuity of ECUIG fuse.
OK:
Continuity
F12740
NG
Check for short circuit in all the harness and

components connected to ECUIG fuse (See attached wiring diagram.
OK
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DIAGNOSTICS

DI153
DI7Z401
DTC
58
CIRCUIT DESCRIPTION
DTC No.
Trouble Area
58
Stop light switch circuit is open circuit, and stop light switch
voltage is in the level between 65 % or more and less
than 93 % of the battery voltage.
S Stop light switch

S ECU
WIRING DIAGRAM
Sedan:

STOP 10A 10
1
IA
IG
WR *5
W *6
1 F17
ALT
140A *7
120A *8
100A *9
1 F15
B *7
BG *8
W *9
Stop Light
Switch
W
GW
1
Center J/B
21
3F
ABS ECU with

Actuator
21
3D
GW
14
A6 STP
8 3C
Fusible
Link
Block
GW
6
5
ID1 II1
*5 *6
GW
F *1 F *1
GW
J/C
FL
Main
1
3.0W *7,*8
2.0L *9
2
Battery
D *2 D *2 GW
GW
6
2
Stop
Stop Light
Light LH
RH
4 WB
WB 4
A *4 A *4
A *4
High
Mounted
Stop
Light
J/C
A *3
WB
*3
WB
WB
BL *5
BN *6
BM
*1: J12(LHD), J28(RHD)

*2: J13(LHD), J29(RHD)
*3: J10 (LHD), J30 (RHD)
*4: J11 (LHD), J31 (RHD)
*5: LHD
*6: RHD
*7: 1CDFTV
*8: 1AZFSE
*9: 1ZZFE,3ZZFE,3SFE
F13602
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DI154
DIAGNOSTICS

Lift Back (LHD):

Stop Light
Switch

STOP 10A 10
1
IA
IG
WR
140A *1
1
120A *2
F17
Fusible
100A *3 GW
Link
Block
ALT
21
3D
GW
GW
6
ID1
GW
D J14 D J14
J/C
High
Mounted
Stop
Light
GW
GW
3
Stop
Stop Light
Light RH
LH
3
5 WB
WB
E J15
E J15 B J15
WB
J/C
E J14
WB
E J14 B J14
WB
*1:1CDFTV
*2:1AZFSE
*3:1ZZFE,3ZZFE,3SFE
WB
BO
BQ
BP
ABS ECU with

Actuator
Lift Back (RHD):

STOP 10A 10
1
IA
IG
Stop Light
Switch
1 F17
Center J/B
W
2
GW
21
3F
GW
1
W
140A *1
120A *2
100A *3
14
A6 STP
8 3C
F J15 F J15
Battery
21
3F
GW
1 BD1
1 F15
B *1
BG *2
GW
W *3
FL
1
Main
3.0W *1,*2
2.0L *3
2
Center J/B
W
2
ABS ECU with

Actuator
GW
21
3D
GW
14
A6 STP
8 3C
5
II1
GW
Fusible
Link
ALT
E J33 D J32
Block
1 BD1
1 F15
J/C
1
B*
E J33 E J33
BG *2
GW
GW
3
W*
FL
GW
Main
High
1
3
5
1,
2
3.0W * *
Stop
Stop Light
Mounted
2.0L *3
Light LH
RH
Stop
2 Light
5
3
Battery
WB
BQ
WB
BP
WB
BO
*1:1CDFTV
*2:1AZFSE
*3:1ZZFE,3ZZFE,3SFE
F13603
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DIAGNOSTICS

Wagon:
WR *1
W *2
1
IA
STOP 10A 10
IG
1 F17
140A *3
Fusible
120A *4
Link
ALT 100A *5
Block
GW
2
J16 *1
J34 *2
6
5
ID1 II1
*1 *2
GW
B
W *5
21
3F
21
3D
GW
14
A6 STP
8 3C
GW
J17 *1
J35 *2
1 F15
B *3
BG *4
ABS ECU with

Actuator
Stop Light
Switch
DI155
FL
GW High
GW
Main
Mounted 2
1
Stop
3.0W *3,*4
Stop
Light LH
2.0L *5
Light
2
4 WB
A WB
A
Battery
A WB
GW
2
Stop Light
RH
4 WB
A
J17 *1
J35 *2
J/C
A WB
BS
BR
*1:LHD
*2:RHD
*3:1CDFTV
*4:1AZFSE
*5:1ZZFE,3ZZFE,3SFE
F13604
1
CHECK:
Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released.
NG
Repair stop light circuit (See Pub. No. RM599E

on BE57).
OK
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DI156
()
DIAGNOSTICS

Check voltage between terminal STP of ABS actuator and body ground.
PREPARATION:
CHECK:
Measure voltage between terminal STP of ABS actuator harness side connector and body ground when brake pedal is depressed.
OK:
Voltage: 8 14 V
(+)
STP
F00069
OK

NG
Check for open circuit in harness and connector between ABS ECU and stop
light switch (See page IN30).
NG
OK
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DIAGNOSTICS

DI157
DI7Z501
DTC
62
ABS ECU Malfunction
CIRCUIT DESCRIPTION
DTC No.
62
Trouble Area
ABS ECU continuously detected the inproper operation of

ABS.
S Battery
S ECU
1
Is DTC output?
Check DTC on page DI129.

YES
Repair circuit indicated by the output code.
YES
Check for short circuit in harness and connector between DLC3 and ABS ECU (See page
IN30).
NO
Is normal code displayed?
NO
Does ABS warning light go off?
YES
Check open and short circuit of the harness and

connector in the Tc circuit between ECU and
DLC3.
NO
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DI158
DIAGNOSTICS

Check voltage between terminals IG1 and GND of ABS actuator connector.
PREPARATION:
CHECK:
(b) Measure voltage between terminals IG1 and GND of ABS
actuator harness side connector.
OK:
Voltage: 10 14 V
ON
IG1
(+)
()
GND
F00067
YES
Check for open or short circuit in harness and

connector between ECUIG fuse and ABS actuator (See page IN30).
OK
Check connection of ABS actuator connector.
CHECK:
(a) Check the connection of the ABS actuator connector.
(b) Check the ABS warning light goes off.
OK
NG
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DIAGNOSTICS

DI159
DI7Z601
ABS Warning Light Circuit

CIRCUIT DESCRIPTION
If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At
this time, the ECU records a DTC in memory.
Connecting terminals Tc and CG of the DLC3 makes the ABS warning light blink and output the DTC.
WIRING DIAGRAM

10 RL
5
IC
IF
Center J/B
PL
20
A6 WA
Combination
Meter
BY
Ignition S/W
10
C11
10 RL 9
C11
3F
1 RL 22
3F
C11
10
3A
ABS Actuator
with ECU
ABS Warning
Light
W
5

3
IC
AM1
40A
Fusible Link
Block
2 W(LHD) 2
F17
IA
1
F17
W(RHD)
1
F15
140A
120A
100A
*1
*2
*3
B (*1)
BG (*2)
W (*3)
Battery
FL Main
3.0W (*1, *2)
2.0L (*3)
*1: 1CDFTV
*2: 1AZFSE
*3: 1ZZFE, 3ZZFE, 3SFE
F13405
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DI160
DIAGNOSTICS

Troubleshoot in accordance with the chart below for each trouble symptom.
ABS warning light does not light up
Go to step 1
ABS warning light remains ON
Go to step 2
Check ABS warning light.
See combination meter troubleshooting (See Pub. No. RM599E on page BE57).
NG
Repair bulb or combination meter assembly.
OK
Check for open circuit in harness and connector between GAUGE fuse and ABS ECU (See page
IN30).
Is DTC output?

YES
NO
Check for short circuit in harness and connector between ABS warning light, DLC3 and ECU (See
page IN30).
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DIAGNOSTICS

DI161
DI7Z701
BRAKE Warning Light Circuit

CIRCUIT DESCRIPTION
The BRAKE warning light lights up when the brake fluid is insufficient, parking brake is applied or the EBD
is defective.
WIRING DIAGRAM
ABS Actuator
with ECU
P2
Parking Brake
Switch
1 RW

5
GAUGE 10 RL
IF
IC
10A
Center J/B
1
3F
10
3F
10
3A
2
2
IC4 IC3
(RHD) (LHD)
RW
13
A6 PKB
BRAKE Warning
Light
5
21
22
RL
RW
C11
A6 EBDW
C11
9
RL
C11
Combination
Meter
BY
Ignition S/W
W
5
3
IC
AM1
40A
Fusible Link
Block
1
2 W(LHD) 2
1A
F17
1
F17
W(RHD)
*1: 1CDFTV
*2: 1AZFSE
*3: 1ZZFE, 3ZZFE, 3SFE
ALT
140A *1
120A *2
100A *3
1
F15
B (*1)
BG (*2)
W (*3)
FL Main
3.0W (*1, *2)
2.0L (*3)
Battery
F13406
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DI162
DIAGNOSTICS

1
Check parking brake switch circuit (See Pub. No. RM599E on page BE45).
NG
Repair or replace parking brake switch circuit.
OK
Check brake fluid level warning switch circuit (See Pub. No. RM599E on page
BE45).
NG
Repair or replace brake fluid level warning

switch circuit.
Yes
OK
Is DTC output for ABS ?
No
Check brake warning light.
NG
Repair or replace combination meter.
OK
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DIAGNOSTICS

Check for open or short circuit in harness and connector (See page IN30).
NG
OK
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DI163
DI164
DIAGNOSTICS

DI7Z801
Tc Terminal Circuit
CIRCUIT DESCRIPTION
Connecting between terminals Tc and CG of the DLC3 causes the ECU to display the DTC by flashing the
ABS warning light.
WIRING DIAGRAM
ABS ECU with
Actuator
DLC3
WB
4
A
J/C
CG
J44 J/C
Tc
LGR
LGR
13
12
A6 Tc
J1 (LHD)
J27 (RHD)
II (LHD)
IJ (RHD)
F04476
1
Check voltage between terminals Tc and CG of DLC3.

CHECK:
(b) Measure voltage between terminals Tc and CG of DLC3.
OK:
Voltage: 5.7 8.1 V
Tc
CG
DLC3
F09678
OK
If ABS warning light does not blink even after Tc

and CG are connected, the ECU may be defective.
NG
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DIAGNOSTICS

DI165
Check for open and short circuit in harness and connector between ABS ECU
and DLC3, DLC3 and body ground (See page IN30).
NG
OK
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DI166
DIAGNOSTICS

DI7Z901
Ts Terminal Circuit
CIRCUIT DESCRIPTION
The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with
the DTC check.
Connecting terminals Ts and CG of the DLC3 on the lower finish panel starts the check.
WIRING DIAGRAM
ABS ECU with
Actuator
DLC3
WB
4
A
J/C
CG
Ts
RB
14
11
A6 Ts
J1 (LHD)
J27 (RHD)
II (LHD)
IJ (RHD)
F04477
1
Check voltage between terminals Ts and CG of DLC3.

CHECK:
(b) Measure voltage between terminals Ts and CG of DLC3.
OK:
Voltage: 5.7 8.1 V
Ts
DLC3
CG
F04969
OK
If ABS warning light does not blink even after Ts

NG
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DIAGNOSTICS

DI167
Check for open and short circuit in harness and connector between ABS ECU
and DLC3 and body ground (See page IN30).
NG
OK
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DI168
DIAGNOSTICS

DI7ZA01

Check for fluid leakage from actuator or hydraulic lines.
F04266
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DI169
DIAGNOSTICS

DI7ZB01

Troubleshoot in accordance with the procedure on the following pages.
Items inside
with the page number in the bottom portion. See
the pages for detailed explanations.

P. DI170

P. DI171
Symptom
does not occur
Symptom Simulation
P. IN20

P. DI181
Symptom
occurs
Normal code
DTC Check
P. DI171
Malfunction code
DTC Chart
P. DI176
Circuit Inspection
9
Sensor Check
P. DI182 DI252

P. DI254
10
11
Repair
Confirmation Test
Step 2, 5, 8, 9, 11: Diagnostic steps permitting the use of the

handheld tester or breakoutbox.
End
Fail safe function:
When a failure occurs in the ABS & BA & TRC & VSC system, the respective warning light (ABS, VSC) is lit and
the operation of ABS & BA & TRC & VSC is prohibited. In addition to this, when the failure which disables the EBD
operation occurs, the brake warning light is lit as well and the EBD operation is prohibited.
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DI170
DIAGNOSTICS

DI7ZC01

ABS & BA & TRC & VSC Check Sheet
Inspectors
:
Name
Registration No.
Registration Data
Customers Name
Frame No.
Date Vehicle
Brought In
km
miles
Odometer Reading
Continuous
/
Intermittent (
times a day)

ABS does not operate efficiently.
TRC does not operate.
VSC does not operate. (Wheels spin when starting rapidly.)
BA does not operate.
Symptoms
Check Item
ABS Warning Light

Abnormal
Remains ON
Does not Light Up
VSC OFF Indicator

Light Abnormal
Remains ON
Does not Light Up
VSC Warning
Light Abnormal
Remains ON
Does not Light Up
SLIP Indicator
Light Abnormal
Remains ON
Does not Light Up
BRAKE Warning
Light Abnormal
Remains ON
Does not Light Up
Malfunction
Indicator Light
Normal
Does not Light Up
1st Time
Normal Code
2nd Time
Normal Code
DTC Check
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DI171
DIAGNOSTICS

DI7ZD01
PRECHECK
1.
(a)
F12737
DIAGNOSIS SYSTEM
Check the warning lights.
(1) Release the parking brake lever.
(2) When the ignition switch is turned ON, check that
the ABS warning light, VSC warning light, VSC OFF
indicator light, BRAKE warning light and SLIP indicator light goes on for approx. 2 seconds.
HINT:
S
S
When the parking brake is applied or the level of the brake

fluid is low, the BRAKE warning light is lit.
If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit, VSC warning light circuit, VSC OFF indicator light circuit, BRAKE
warning light circuit or SLIP indicator light circuit.
Trouble Area
ABS warning light circuit
DI231, DI225
VSC warning light circuit
DI233, DI228
VSC OFF indicator light circuit
DI243
BRAKE warning light circuit
DI236
SLIP indicator light circuit
DI240
(b)
Tc
See page
DLC3
In case of not using handheld tester:

Check the DTC of ABS & BA & TRC & VSC ECU.
SST 0984318040
(3) Read the DTC from the ABS warning light and VSC
warning light on the combination meter.
HINT:
CG
F04969
If no code appears, inspect the diagnostic circuit, ABS

warning light circuit or VSC waning light circuit.
Trouble Area
See page
Tc terminal circuit
DI250
ABS warning light circuit
DI231
VSC warning light circuit
DI233
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DI172
DIAGNOSTICS
As an example, the blinking patterns for normal code and

code 31 and 32 are shown on the left.
(4) Codes are explained in the code table on page
DI176.
(5) After completing the check, disconnect terminals Tc
and E1, and turn OFF the display.
If 2 or more malfunctions are indicated at the same time, the
lowest numbered DTC will be displayed 1st.
Normal Code
2 secs.
0.25 secs.
0.25 secs.
ON
OFF
Code 31 and 32
0.5 secs. 0.5 secs.
1.5 secs.
4 secs.
2.5 secs.
ON
OFF
Code 31
Code 32
F04712
Handheld
Tester
DLC3
D01600
(c)
HINT:
Please refer to the handheld tester operators manual for further details.
(d)
BR3890
In case of using handheld tester :

Check the DTC.
(1) Hook up the handheld tester to the DLC3.
(3) Read the DTC by following the prompts on the tester screen.

Clear the DTC.
(1) Using SST, connect terminals Tc and E1 of check
connector.
SST 09843 18040
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 5 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of DLC 3.
SST 09843 18040
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DI173
DIAGNOSTICS
Handheld
Tester
(e)
In case of using handheld tester:

Clear the DTC.
(3) Operate the handheld tester to erase the codes.
(See handheld tester operators manual.)
2.
(a)
SPEED SENSOR SIGNAL CHECK (TEST MODE)

Check the sensor signal.
(2) Using SST, connect terminals Ts and CG of DLC3.
SST 0984318040
DLC3
D01600
Ts
DLC3
CG
F04969
(4)
0.13 sec.
0.13 sec.
ON
OFF
BR3904
Check that the ABS warning light blinks.
HINT:
If the ABS warning light does not blink, inspect the ABS warning
light circuit (See page DI231).
(5) Drive vehicle straight forward.
Drive vehicle at a speed faster than 45 km/h (28 mph) for
several seconds.
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 the vehicle.
SST 0984318040
(8) Read the number of blinks of the ABS warning light.
HINT:
S
See the list of DTC shown on the next page.
S
If every sensor is normal, a normal code is output (A cycle
of 0.25 sec. ON and 0.25 sec. OFF is repeated).
S
If 2 or more malfunction codes are identified at the same
time, the lowest numbered code will be displayed 1st.
Malfunction Code (Example Code 72, 76)

7
ON
OFF
0.5 sec.
1.5 sec.
0.5 sec.
0.5 sec.
2.5 sec.
0.5 sec.
4 sec.
Repeat
BR3893
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DI174
DIAGNOSTICS
(9)
After doing the check, disconnect the SST from terminals Ts and CG, Tc and CG of DLC3, and turn the
ignition switch OFF.
SST 0984318040
Handheld
Tester
(b)
DLC3
D01600
In case of using handheld tester:

Check the sensor signal.
(2) Do step (3) (6) on the previous page and this
page.
(3) Read the DTC by following the prompts on the tester screen.
HINT:
Please refer to the handheld tester operators manual for further details.
DTC of speed sensor check function:

Code No.
Diagnosis
Trouble Area
C1271 / 71
Low output voltage of right front speed sensor

S Right front speed sensor rotor
C1272 / 72
Low output voltage of left front speed sensor

S Left front speed sensor rotor
C1273 / 73
Low output voltage of right rear speed sensor

S Right rear speed sensor rotor
C1274 / 74
Low output voltage of left rear speed sensor

S Left rear speed sensor rotor
C1275 / 75
Abnormal change in output signal of right front speed sensor
Right front speed sensor rotor
C1276 / 76
Abnormal change in output signal of left front speed sensor
Left front speed sensor rotor
C1277 / 77
Abnormal change in output signal of right rear speed sensor
Right rear speed sensor rotor
C1278 / 78
Abnormal change in output signal of left rear speed sensor
Left rear speed sensor rotor
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DI175
DIAGNOSTICS
3.
STEERING ANGLE SENSOR ZERO POINT CALIBRATION

NOTICE:
When replacing the steering angle sensor with column assembly or ABS & BA & TRC & VSC ECU, Engine and ECT
ECU (A/T), Engine ECU (M/T) or when adjusting the front
wheel alignment or steering wheel center point in accordance with the removing and installing or replacing the
suspension, axle or steering parts, make sure to perform
steering angle sensor zero point calibration.
(a) Using SST, connect terminals Ts and CG of DLC3.
SST 0984318040
(c) Make sure the steering off center angle is less than 3
when assembling of steering wheels (Smaller value is desirable).
(d) Press the VSC OFF switch and hold it.
HINT:
(e) Depress the brake pedal 3 times or more within 2 seconds.
(f)
Check that the VSC buzzer sounds for 3 seconds.
HINT:
S
Press and hold the VSC OFF switch until VSC buzzer
sounds.
When it starts sounding, turn off the switch.
S
When the VSC buzzer starts sounding, turn off the VSC
OFF switch.
S
If the VSC buzzer sounds, the sensor calibration is in normal completion.
S
If the VSC buzzer does not sound, do the sensor calibration again.
S
If the VSC buzzer still will not sound, there is malfunction
in the steering angle sensor, so check the DTC.
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DI176
DIAGNOSTICS

DI7ZE01

NOTICE:
S
When removing the part, turn the ignition switch OFF.
S
When replacing the steering angle sensor or ECU, make sure to perform steering angle sensor
zero point calibration.
HINT:
S
Using SST 0984318040, connect the terminals Tc and CG of the DLC 3.
S
If any abnormality is not found when inspecting parts, inspect the ECU.
S
If a malfunction code is displayed during the DTC check, check the circuit listed for the code. For details
of each code, refer to the page under the See page for respective DTC No. in the DTC chart.
DTC chart of ABS system:
DTC No.
(See Page)
Detection Item
Trouble Area
C0278 / 11
(DI190)
Open or short circuit in ABS solenoid relay circuit
S ABS solenoid relay

S ABS solenoid relay circuit
C0273 / 13
(DI189)
Open or short circuit in ABS motor relay circuit
S ABS motor relay

S ABS motor relay circuit
C0226 / 21
(DI188)
Open or short circuit in brake actuator
S Brake actuator
S SFRR or SFRH circuit
C0236 / 22
(DI188)
S Brake actuator
S SFLR or SFLH circuit
C0246 / 23
(DI188)
S Brake actuator
S SRRR or SRRH circuit
C0256 / 24
(DI188)
S Brake actuator
S SRLR or SRLH circuit
C0200 / 31
(DI182)
Right front wheel speed sensor signal malfunction
C0205 / 32
(DI182)
Left front wheel speed sensor signal malfunction
C0210 / 33
(DI182)
Right rear wheel speed sensor signal malfunction
C0215 / 34
(DI182)
Left rear wheel speed sensor signal malfunction
C1330 / 35
(DI182)
Open circuit in right front speed sensor circuit

S Right front speed sensor circuit
C1331 / 36
(DI182)
Open circuit in left front speed sensor circuit

S Left front speed sensor circuit
C1237 / 37
(DI206)
Front tires are different from rear in size.
S Tire size
S Speed sensor rotor
C1332 / 38
(DI182)
Open circuit in right rear speed sensor circuit

S Right rear speed sensor circuit
C1333 / 39
(DI182)
Open circuit in left rear speed sensor circuit

S Left rear speed sensor circuit
C1241 / 41
(DI208)
Low battery positive voltage or abnormally high battery positive

voltage
S Battery
S Charging system
C1249 / 58
(DI215)
Open circuit in stop light switch circuit
S Stop light switch

S Right front, left front, right rear and left rear speed sensor
S Each
E h speed
d sensor circuit
i it
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DI177
DIAGNOSTICS
C1300 / 62
(DI220)
Malfunction in ABS & BA & TRC & VSC ECU
ABS & BA & TRC & VSC ECU
Always ON
(DI225)

Open circuit in ABS warning light circuit
S Charging system
S ABS warning light circuit
DTC chart of VSC system:

DTC No.
(See Page)
Detection Item
C1225 / 25
(DI188)
Open or short circuit in brake actuator solenoid circuit (SMC1

circuit)
S Brake actuator
S SMC1 circuit
C1226 / 26
(DI188)
Open or short circuit in brake actuator solenoid circuit (SMC2

circuit)
S Brake actuator
S SMC2 circuit
C1227 / 27
(DI188)
Open or short circuit in brake actuator solenoid circuit (SRC1

circuit)
S Brake actuator
S SRC1 circuit
C1228 / 28
(DI188)
Open or short circuit in brake actuator solenoid circuit (SRC2

circuit)
S Brake actuator
S SRC2 circuit
C1301 / 42
(DI222)
Malfunction in CAN communication (steering angle circuit, yaw

rate sensor circuit)
S Steering angle sensor circuit

S Yaw rate sensor circuit
S ABS & BA & TRC & VSC ECU
C0365 / 43
(DI191)
Malfunction in deceleration sensor (combined in yaw rate sensor)
S Deceleration sensor
S Deceleration sensor circuit
C1202 / 44
(DI197)
Open or short circuit in NE signal circuit
C1350 / 51
(DI221)
Pump motor is locked

Open circuit in pump motor ground
S Brake actuator pump motor

S Brake actuator pump motor circuit
C1246 / 53
(DI212)
Malfunction in master cylinder pressure sensor
S Master cylinder pressure sensor

S Master cylinder pressure sensor circuit
C1208 / 54
(DI202)
Malfunction in steering angle sensor
S Steering angle sensor

C0371 / 55
(DI194)
Malfunction in yaw rate sensor circuit
S Yaw rate sensor

Always ON
(DI228)

Open circuit in VSC warning light circuit
S Charging system
S VSC warning light circuit
Malfunction in ENGINE and ECT ECU (A/T) or ENGINE ECU

(M/T) and ABS & BA & TRC & VSC ECU circuit
S ENGINE and ECT ECU (A/T) or ENGINE ECU (M/T)

S Serial communication circuit
Malfunction in ENGINE and ECT ECU (A/T) or ENGINE ECU

(M/T) version

S Steering angle sensor zero point calibration
C1203 / 59
(DI200)
C1288 / 88
(DI219)
Trouble Area
S NEO circuit
S Engine and ECT ECU (A/T) or Engine ECU (M/T)
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DI178
DIAGNOSTICS

DI7ZF01
PARTS LOCATION
Combination Meter
DABS Warning Light
DVSC Warning Light
DBRAKE Warning Light
DVSC OFF Indicator Light
DSLIP Indicator Light
Rear Speed Senser
Yaw Rate Sensor

(Including Deceleration Sensor)
Steering Angle Sensor
Front Speed Sensor
DLC3
Rear Speed Senser
Rotor
Front Speed Sensor
Rotor
ABS & BA & TRC & VSC ECU with Actuator
DMaster Cylinder Pressure Sensor
DRelay
F12739
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DI179
DIAGNOSTICS

DI7ZG01
TERMINALS OF ECU
ABS & BA & TRC & VSC ECU:
A29
F12741

WT (A29 2) GND (A29 6
6, 10)
IND (A29 4) GND (A29 6,

6 10)
+BS (A29 5) GND (A29 6, 10)
Wiring Color
O WB
W B
WB
W B
Condition
IG switch ON, VSC OFF indicator light ON
Below 2.0
IG switch ON, VSC OFF indicator light OFF
10 14
IG switch ON, SLIP indicator light ON
Below 2.0
IG switch ON, SLIP indicator light OFF
10 14
B WB
ENG+ (A29 8) ENG (A29 7)
RL
+BM (A29 9) GND (A29 6, 10)
B WB
STD Voltage (V)
10 14
Engine idling
Pulse generation
10 14
PMC (A29 11) GND (A29 6, 10)
LG WB
IG switch ON, brake pedal released
0.3 0.8
E2 (A29 12) GND (A29 6, 10)
BR WB
IG switch OFF
continuity
SS1 (A29 13) GND (A29 6, 10)
W WB
IG switch ON
Pulse generation
IG1 (A29 14) GND (A29 6, 10)
BR WB
IG switch ON
1014
BZ (A29 15) GND (A29 6

6, 10)
G WB
W B
YGND (A29 16) YIGA (A29 30)
BRW LGR
IG switch ON, VSC buzzer sounds

IG switch ON, VSC buzzer does not sound
Engine idling, slowly turn steering wheel
Below1.0 1014
1014
Pulse generation
TC (A29 17) GND (A29 6,

6 10)
LG R WB
LGR
W B
IG switch ON
10 14
TRC+ (A29 18) TRC (A29 19)
YB
Engine idling
Pulse generation
EBDW (A29 20) GND (A29 6,

6 10)
FR (A29 21) FR
FR+
FR (A29 22)
RL+ (A29 23) RL (A29 40)
R W WB
RW
W B
WR *1 B
W *2 B
Y BR
IG switch ON, BRAKE warning light ON
Below 1.5
IG switch ON, BRAKE warning light OFF
10 14
IG switch ON,
ON slowly turn right front wheel
AC generation
IG switch ON, slowly turn left rear wheel
AC generation
D/G (A29 26) GND (A29 6,

6 10)
LG R WB
LGR
W B
IG switch
it h ON
10 14
VCM (A29 27) GND (A29 6, 10)
LY WB
IG switch ON
4.5 5.5
TS (A29 28) GND (A29 6, 10)
RB WB
IG switch ON
10 14
SS2 (A29 29) GND (A29 6, 10)
B WB
IG switch ON
Pulse generation
PKB (A29 31) GND (A29 6,

6 10)
R W WB
RW
W B
NEO (A29 32) GND (A29 6,

6 10)
P WB
W B
VSCW (A29 34) GND (A29 6,

6 10)
R WB
W B
IG switch ON, parking brake switch ON
Below 2.0
IG switch ON, parking brake switch OFF
10 14
Engine idling
Pulsegeneration
Pulse
generation
IG switch ON, VSC warning light ON
Below 2.0
IG switch ON, VSC warning light OFF
10 14
*1:
LHD
*2: RHD
http://vnx.su
DI180
DIAGNOSTICS
WA (A29 35) GND (A29 6,

6 10)
SP1 (A29 36)*3 GND (A29 6
6, 10)
STP (A29 37) GND (A29 6
6, 10)
P L WB
PL
W B
LW
WB
B
G W WB
GW
W B
P
RR (A29 38) RR
RR+
RR (A29 39)
FL+ (A29 41) FL (A29 24)
CSW (A29 42) GND (A29 6
6, 10)
LR*1
P L*2
IG switch ON, ABS warning light ON
10 14
IG switch ON, ABS warning light OFF
Below 2.0
Vehicle driving at about 20 km/h (12 mph)
Pulsegeneration
Pulse
generation
Stop light switch ON (Brake pedal pushed)
8 14
Stop light switch OFF (Brake pedal released)
Below 1.5
IG switch ON,
ON slowly turn right rear wheel
AC generation
R LW
IG switch ON, slowly turn left front wheel
AC generation
GW*1 WB
IG switch ON, VSC OFF switch pushed in
Below 1.5
GR*2 WB
IG switch ON, VSC OFF switch released
814
*1:
LHD
RHD
*3: A/T vehicle only
*2:
http://vnx.su
DI181
DIAGNOSTICS

DI7ZH01

If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each
problem symptom in the order given in the table below and proceed to the relevant troubleshooting page.
NOTICE:
When replacing ABS & BA & TRC & VSC ECU, sensor, etc., turn the IG switch OFF.
Symptom
Suspect Area
ABS does not operate
Only when 1. 4. are all normal and the problem is still

occurring, replace the ABS & BA & TRC & VSC ECU.
1. Check the DTC, reconfirming that the normal code is
output.
2. IG power source circuit
4. Check the brake actuator with a handheld tester.
If abnormal, check the hydraulic circuit for leakage.
ABS does not operate efficiently

output.
4. Check the brake actuator with a handheld tester.
If abnormal, check the hydraulic circuit for leakage.
ABS warning light abnormal

2. ABS & BA & TRC & VSC ECU
DTC check cannot be done

2. VSC warning light circuit
3. Tc terminal circuit
Speed sensor signal check cannot be done
1. Ts terminal circuit
VSC does not operate
Only when circuits inspected for each problem symptom

are all normal and the problem is still occurring, replace the
ABS & BA & TRC & VSC ECU.
output.
2. IG power source circuit
3. Hydraulic circuit for leakage
See page
DI171
DI208
DI182
DI182
DI171
DI182
DI215
DI215
DI231
DI231
DI233
DI250
DI252
DI171
DI208
DI254
DI182
BA does not operate
Stop light switch circuit
DI215
SLIP indicator light abnormal
SLIP indicator light circuit
DI240
BRAKE warning light abnormal
1. BRAKE warning light circuit

DI236
VSC OFF indicator light abnormal
Only when circuits inspected for each problem symptom

are all normal and the problem is still occurring, replace the
ABS & BA & TRC & VSC ECU.
1. VSC OFF indicator light circuit
2. VSC OFF switch circuit
http://vnx.su
DI243
DI243
DI182
DIAGNOSTICS

DI7ZI01
CIRCUIT INSPECTION
DTC
C0200 / 31 C1331 / 36
DTC
C1332 / 38, C1333 / 39
CIRCUIT DESCRIPTION
Rotor
The speed sensor detects a wheel speed and sends the appropriate signals to the ECU. These signals are used to control
of the ABS and VSC system. Each of the front and rear rotors
has 48 serrations.
When the rotors rotate, a magnetic field emitted by a permanent
magnet in the speed sensor generates an AC voltage. Since
the frequency of this AC voltage changes in direct proportion to
the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel.
Speed Sensor
S Magnet
N
Coil
To ECU
Low Speed
High Speed
+V
BR3583
BR3582
F00010
DTC No.
Trouble 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.
speed has reached 12 km/h (7 mph), the wheel speed of
0 km/h (0 mph) is detected.
speed has reached 18 km/h (11 mph), the front wheel
speed of 0 km/h (0 mph) is detected.
S Tire size
C1330 / 35
C1331 / 36
C1332 / 38
C1333 / 39
Detecting abnormality in the resistance value of each speed

sensor.
HINT:
S
S
S
S
DTC
DTC
DTC
DTC
No.
No.
No.
No.
C0200
C0205
C0210
C0215
/
/
/
/
31 and C1330 / 35 are for the right front speed sensor.

32 and C1331 / 36 are for the left front speed sensor.
33 and C1332 / 38 are for the right rear speed sensor.
34 and C1333 / 39 are for the left rear speed sensor.
http://vnx.su
DI183
DIAGNOSTICS
WIRING DIAGRAM
ABS & BA & TRC
& VSC ECU
A7
Left Front
Speed Sensor
41
A29 FL+
LW
24
A29 FL
(Shielded)
(RHD)
W
A8
Right Front
Speed Sensor
1
R (LHD)
B (RHD)
2
J1 (LHD)
J20 (RHD)
Junction
Connector
2
IH2
3
IH2
(Shielded)
(LHD)
Y
1
11
ID1
II
22
A29 FR
B
(Shielded)
(RHD)
(Shielded)
(LHD)
9
9
IC1 ID1
(RHD) (LHD)
10 10
IC1 ID1
(RHD)(LHD)
2
BR (LHD)
B (RHD)
7
II1
A27
Right
Rear
Speed
Sensor
21
A29 FR+
WB
A26
Left
Rear
Speed
Sensor
WR (LHD)
W (RHD)
1
IH2
P
1
23
A29 RL+
BR
40
A29 RL
(Shielded) (RHD)
7
8
II1 II1
(RHD) (LHD)
8
9
II1 II1
(RHD)(LHD)
2
V (LHD)
L (RHD)
(Shielded)
(RHD)
LR (LHD)
L (RHD)
38
A29 RR+
39
A29 RR
F13392
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DI184
DIAGNOSTICS
1
Check speed sensor.
1
2
R14205
R14213
Front:
PREPARATION:
(a) Remove the front fender liner.
CHECK:
Measure the resistance between terminals 1 and 2 of speed
sensor connector.
OK:
CHECK:
sensor connector and body ground.
OK:
Rear:
PREPARATION:
(a) Remove the seat cushion and seatback.
CHECK:
sensor connector.
OK:
CHECK:
sensor connector and body ground.
OK:
NG
NOTICE:
OK
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DI185
DIAGNOSTICS
Check for open and short circuit in harness and connector between each speed
sensor and ABS & BA & TRC & VSC ECU (See page IN30).
NG
OK
Check speed sensor installation.

CHECK:
Check the speed sensor installation.
OK:
The installation bolt shall be tightened properly and
no clearance is allowed between the sensor and front
steering knuckle or rear axle carrier.
OK
NG
BR3795
NG
NOTICE:
OK
http://vnx.su
DI186
DIAGNOSTICS
Check speed sensor and sensor rotor serrations.

Normal Signal Waveform
GND
2 m/s / Division
1 V / Division
W04200
REFERENCE: INSPECTION USING OSCILLOSCOPE

PREPARATION:
(a) Disconnect the connector from the ABS & BA & TRC &
VSC ECU.
(b) Connect the oscilloscope to the terminals FR+, FL+, RR+
or RL+ and GND of the ECU harness side connector.
CHECK:
Drive the vehicle at about 30 km/h (19 mph), and check the signal waveform.
OK
Check and replace ABS & BA & TRC & VSC ECU
with actuator assembly.
NG
Check sensor rotor and sensor tip.
R00948
Front:
PREPARATION:
Remove the front drive shaft (See page SA3).
CHECK:
OK:
No scratches, missing teeth or foreign objects.
PREPARATION:
Remove the front speed sensor (See Pub. No. RM599E on
page BR41).
CHECK:
OK:
http://vnx.su
DI187
DIAGNOSTICS
R00947
Rear:
PREPARATION:
Remove the axle hub ( See Pub. No. RM599E on page SA10).
CHECK:
OK:
No scratches, missing teeth or foreign objects.
PREPARATION:
Remove the rear speed sensor (See Pub. No. RM599E on
page BR44).
CHECK:
OK:
NG
Replace sensor rotor or speed sensor.
NOTICE:
OK
Check and replace ABS & BA & TRC & VSC

ECU with actuator assembly.
http://vnx.su
DI188
DIAGNOSTICS

DI7ZJ01
DTC
C0226 / 21 C1228 / 28
Brake Actuator Solenoid Circuit
CIRCUIT 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.
C0226 / 21
Trouble Area
1. Solenoid signal does not match the check result.

2. Solenoid open & short.
S Brake actuator
S SFRR or SFRH circuit
C0236 / 22
S Brake actuator
S SFLR or SFLH circuit
C0246 / 23
S Brake actuator
S SRRR or SRRH circuit
C0256 / 24
S Brake actuator
S SRLR or SRLH circuit
C1225 / 25
Solenoid signal does not match the check result.
S Brake actuator
S SMC 1 circuit
C1226 / 26
S Brake actuator
S SMC 2 circuit
C1227 / 27
S Brake actuator
S SRC 1 circuit
C1228 / 28
S Brake actuator
S SRC 2 circuit
1
PREPARATION:
CHECK:
NO
No problem.
YES

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DI189
DIAGNOSTICS

DI7ZK01
DTC
C0273 / 13
ABS Motor Relay Circuit
CIRCUIT DESCRIPTION
The ABS motor relay supplies power to the ABS pump motor. When the ABS is activated, the ECU switches
the ABS motor relay ON and operates the ABS pump motor.
DTC No.
Trouble Area
C0273/13
When any of the following 1. through 2. is detected:

1. Pump motor voltage is high, and the motor relay will not
actuate .
2. Pump motor voltage remains low for longer 0.4 sec. or
more and the pump repeats activating for 0.7 sec. 3
times maximally. After the last activation, the pump motor is deactivated gone dead because of short circuit.
S ABS motor relay

S ABS motor relay circuit
1
PREPARATION:
(c) Turn the ignition switch ON.
CHECK:
Vehicle speed is more than 6 km/h (4 mph), and check if the same DTC is stored in the memory.
NO
No problem.
YES

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DI190
DIAGNOSTICS

DI7ZL01
DTC
C0278 / 11
ABS Solenoid Relay Circuit
CIRCUIT DESCRIPTION
This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is
OK, the relay goes on.
DTC No.
C0278 / 11
Trouble Area

1. 3 or more solenoids are show faulty in response and
simultaneously solenoid supply voltage is detected
faulty.
2. Solenoid relay will not be switched OFF.
S ABS solenoid relay

S ABS solenoid relay circuit
1
PREPARATION:
CHECK:
NO
No problem.
YES

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DI191
DIAGNOSTICS

DI7ZM01
DTC
C0365 / 43
Deceleration Sensor Circuit
CIRCUIT DESCRIPTION
Deceleration sensor is combined with yaw rate sensor.
DTC No.
C0365 / 43

1. Deceleration difference between sensor signal and reference value is large.
2. Offset value of sensor signal is higher than the standard
value.
Trouble Area
S Deceleration sensor
S Deceleration sensor circuit
http://vnx.su
DI192
DIAGNOSTICS
WIRING DIAGRAM
ABS & BA & TRC

& VSC ECU
Deceleration Sensor
4
UBAT Y1
2
GND Y1
LGR
30
A29 YIGA
BRW
16
A29 YGND
(Shielded)
(LHD)
(Shielded)
3
CANH Y1
13
A29 SS1
1
CANL Y1
29
A29 SS2
(Shielded)
(LHD)
Center J/B
13
3A
WB
WB
Center J/B
4
3F
WB
9
3F
9
3E

4
IE
11
IH
WB
*1: IH (LHD)
IK (RHD)
*1
F13393
http://vnx.su
DI193
DIAGNOSTICS
HINT:
Start the inspection from step 1 in case of using the handheld tester and start from step 2 in case of not
using the handheld tester.
Check output value of the deceleration sensor.
F13408
PREPARATION:
(a) Remove the 2 bolts and deceleration sensor with connector still connected.
(b) Connect the handheld tester to the DLC3
(c) Turn the ignition switch ON and push the handheld tester main switch ON.
(d) Select the DATALIST mode on the handheld tester.
(e) Check the deceleration value 0 0.23 G.
CHECK:
Check that the yaw rate value of the deceleration sensor displayed on the handheld tester is changing: Place the yaw rate
sensor vertically to the ground and turn the sensor pivoted on
its center.
OK:
Deceleration value must be changing.
OK
Check for open and short circuit in harness and connector between deceleration
NG
OK

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DI194
DIAGNOSTICS

DI7ZN01
DTC
C0371 / 55
Yaw Rate Sensor Circuit
CIRCUIT DESCRIPTION
DTC No.
C0371 / 55

1. The voltage of sensor signal is out of range.
2. The offset value of sensor signal is outside the plausible
range.
3. Sensor signal change rapidly under normal driving.
4. Sensor is more or worse sensitivity than reference yaw
rate during cornering.
Trouble Area
S Yaw rate sensor

http://vnx.su
DI195
DIAGNOSTICS
WIRING DIAGRAM
ABS & BA & TRC

& VSC ECU
Yaw Rate Sensor

4
UBAT Y1
2
GND Y1
LGR
30
A29 YIGA
BRW
16
A29 YGND
(Shielded)
(LHD)
(Shielded)
3
CANH Y1
13
A29 SS1
1
CANL Y1
29
A29 SS2
(Shielded)
(LHD)
Center J/B
13
3A
WB
WB
Center J/B
4
3F
WB
9
3F
9
3E

4
IE
11
IH
WB
*1: IH (LHD)
IK (RHD)
*1
F13393
http://vnx.su
DI196
DIAGNOSTICS
HINT:
Check output value of the yaw rate sensor.
F12654
PREPARATION:
(a) Remove the 2 bolts and yaw rate sensor with connector
still connected.
(b) Connect the handheld tester to the DLC3.
(c) Turn the ignition switch ON and push the handheld tester main switch ON.
(d) Select the DATALIST mode on the handheld tester.
(e) Check the yaw rate value 0 5 deg/s.
CHECK:
Check that the yaw rate value of the yaw rate sensor displayed
on the handheld tester is changing: Place the yaw rate sensor
vertically to the ground and turn the sensor pivoted on its center.
OK:
Yaw rate value must be changing.
OK
Check for open and short circuit in harness and connector between yaw rate
NG
OK

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DI197
DIAGNOSTICS

DI7ZO01
DTC
C1202 / 44
NE Signal Circuit
CIRCUIT DESCRIPTION
The ABS & BA & TRC & VSC ECU receives engine revolution speed signals (NE signals) from the Engine
and ECT ECU (A/T) or Engine ECU (M/T).
DTC No.
C1202 / 44
Trouble Area
At vehicle speed of 30 km/h (19 mph) or more, and when

data received from the Engine and ECT ECU (A/T) or Engine ECU (M/T) is in normal condition, and open or short
circuit for engine revolution signal circuit continues for 5
secs. or more.
S NEO circuit
S Engine and ECT ECU (A/T) or Engine ECU (M/T)
S ABS & TRC & VSC ECU
WIRING DIAGRAM
Engine ECU (M/T)

15
NEO E13
ABS & BA &TRC &

VSC ECU
32
A29 NEO
F03929
http://vnx.su
DI198
DIAGNOSTICS
1
Check for open and short circuit in harness and connector between terminal
NEO of ABS & BA & TRC & VSC ECU and terminal NEO of Engine and ECT ECU
(A/T) or Engine ECU (M/T) (See page IN30).
NG
OK
Check voltage between terminal NEO of ABS & BA & TRC & VSC ECU and body
ground.
()
PREPARATION:
(a) Remove ABS & BA & TRC & VSC ECU with connectors
still connected.
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal NEO of ABS & BA & TRC
& VSC ECU and body ground for the engine conditions below.
OK:
NEO
ON
(+)
F13390
Engine condition
Voltage
OFF (IG ON)
3 6 V or below 1 V
ON (Idling)
3 6 V below 1 V (Pulse)
(Reference)
36V
Below 1 V
F03007
http://vnx.su
DI199
DIAGNOSTICS
NG
with actuator assembly or Engine and ECT ECU
(A/T) or Engine ECU (M/T).
OK
If the same codes is still output after the DTC is deleted, check the contact condition of each connection.
http://vnx.su
DI200
DIAGNOSTICS

DI7ZP01
DTC
C1203 / 59
EFI Communication Circuit

Malfunction
CIRCUIT DESCRIPTION
The circuit is used to send TRAC & VSC control information from the ABS & BA & TRC & VSC ECU to the
Engine and ECT ECU (A/T) or Engine ECU (M/T) (TRC+, TRC), and engine control information from the
Engine and ECT ECU (A/T) or Engine ECU (M/T) to the ABS & BA & TRC & VSC ECU (ENG+, ENG).
DTC No.
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 to Engine ECU (M/T) or Engine and
ECT ECU (A/T) continues for 1.2 sec. or more.
2. IG1 voltage is 8.5 V or more, engine speed is 500 r.p.m
or more, vehicle speed is 60 km/h (38 mph) or more,
and the condition that data can not be received from
Engine ECU (M/T) or Engine and ECT ECU (A/T) continues for 5 sec. or more.
3. The condition that data can not be transmitted between
the ABS & BA & TRC & VSC ECU and Engine ECU
(M/T) or Engine and ECT ECU (A/T) occurs at least
once within 5 sec. continues 10 consecutive times.
S TRC+ or TRC circuit

S ENG+ or ENG circuit
S Engine ECU (M/T) or Engine and ECT ECU (A/T)
WIRING DIAGRAM
Engine ECU (M/T)

ABS & BA & TRC &

VSC ECU
12
TRC E15
17
TRC+ E15
21 21
IE2 IF2
(RHD) (LHD)
22 22
IE2 IF2
(RHD) (LHD)
19
A29 TRC
18
A29 TRC+
21
ENG E14
7
A29 ENG
22
ENG+ E14
8
A29 ENG+
F13407
http://vnx.su
DI201
DIAGNOSTICS
1
Check for open and short circuit in harness and connector between each of terminals ENG+, ENG, TRC+ and TRC of ABS & BA & TRC & VSC ECU and Engine
ECU (M/T) or Engine and ECT ECU (A/T) (See page IN30).
NG
OK
Check operation of the malfunction indicator.
NG
Check and replace Engine and ECT ECU (A/T) or

Engine ECU (M/T).
OK

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DI202
DIAGNOSTICS

DI7ZQ01
DTC
C1208 / 54
Steering Angle Sensor Circuit
CIRCUIT DESCRIPTION
DTC No.
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 steering
angle sensor continues.
2. Sensor internal failure.
3. The offset value is out of range.
4. Sensor signal change higher.
5. Steering angle value difference between measured and
reference is out of range.
6. Steering sensor is not centered.
7. Steering sensor signal is out of range.
8. Steering sensor is not calibration.
Trouble Area
S Steering angle sensor

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DI203
DIAGNOSTICS
WIRING DIAGRAM
S23
Steering Sensor
ABS & BA & TRC

& VSC ECU
6
12V S23
5
GND S23
LGR
30
A29 YIGA
BRW
16
A29 YGND
(Shielded)
7
CAN
HIGH S23
1
CAN
LOW S23
13
A29 SS1
29
A29 SS2
(Shielded)
(RHD)
Center J/B
13
3A
WB
WB
Center J/B
4
3F
WB
9
3F
9
3E

4
IE
11
IH
WB
*1: IH (LHD)
IK (RHD)
*1
F13394
http://vnx.su
DI204
DIAGNOSTICS
HINT:
Check output value of the steering angle sensor.
PREPARATION:
(b) Turn the ignition switch ON and push the handheld tester main switch ON.
(c) Select the DATALIST mode on the handheld tester.
CHECK:
Check that the steering wheel turning angle value of the steering angle sensor displayed on the handheld
tester is appropriate when turning the steering wheel.
OK:
Steering wheel turning angle value must be appropriate.
OK
Go to step 4.
NG
Check the installation condition of steering angle sensor.
NG
Repair or replace steering angle sensor with

column Assembly (See page SR6).
OK
Check for open and short circuit in harness and connector between steering
angle sensor and ABS & BA & TRC & VSC ECU (See page IN30).
NG
OK
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DI205
DIAGNOSTICS
Calibrate the steering angle sensor (See page DI171).
NG
Replace steering angle sensor with colum Assembly (See page SR6).
OK
Replace the ECU and check whether or not the trouble occurs again.
YES
Replace steering angle sensor with colum Assembly (See page SR6).
NO

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DI206
DIAGNOSTICS

DI7ZR01
DTC
C1237 / 37
Wrong Number of Teeth at 1 of 4 Wheels
CIRCUIT DESCRIPTION
DTC No.
C1237 / 37
Trouble Area

1. When the ignition switch is ON, the speed difference
between the rear right and rear left wheels is 5 km/h
(3mph) or more (vehicle speed: 100 km/h (62 mph) or
less).
2. When the ignition switch is ON, the slip difference between 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. or more.
4. Interference on 1 or more wheels for 20 sec. with the
brake pedal depressed, or for 5 sec. when the brake
pedal is not depressed.
S Tire size
1
Check tire size.
NG
Replace tires so that all 4 tires are the same in

size.
OK
Check sensor rotor (See page DI182).
NG
Replace speed sensor rotor.
OK
Check speed sensor (See page DI182).
NG
OK
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DI207
DIAGNOSTICS
Check for open and short circuit in harness and connector between front speed
sensor, rear speed sensor and ABS & BA & TRC & VSC ECU (See page
IN30).
NG
OK

ECU with actuator.
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DI208
DIAGNOSTICS

DI7ZS01
DTC
C1241 / 41
IG Power Source Circuit
CIRCUIT DESCRIPTION
This is the power source for the ECU, hence the brake actuators.
DTC No.
C1241 / 41
At a vehicle speed of 6 km/h (4 mph) or more, the condition

that low battery voltage is 10 V or less and high battery
voltage is more than 17.4 V.
Trouble Area
S Battery
S Charging system
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DI209
DIAGNOSTICS
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
ECUIG
9
5
IC
IE
BY
I13
Ignition Switch
5
8
IG1
Center J/B
BR
18
3A
18
3D
BR
14
A29 IG1

AM1
2
3
2
1
IA
IC
AM1
W (RHD)
W (LHD)
F17 1
F17 2
Engine Room J/B
ALT
Fusible
Link
Block
3
2F
F15 1
8
2B
WB
10
A29 GND2
2F 1
6
WB
BG
A29 GND1
WB
WB
FL Main
WB
WB
Battery
EB
EA
EY
F13395
http://vnx.su
DI210
DIAGNOSTICS
1
Check ECUIG fuse.

PREPARATION:
Remove the ECUIG fuse from the instrument panel J/B.
CHECK:
Check continuity of the ECUIG fuse.
OK:
Continuity
ECUIG
F12740
NG
Check for short circuit in all the harness and

components connected to ECUIG fuse (See attached wiring diagram).
NG
Check and repair the charging system.
OK
Check battery voltage.
OK:
Voltage: 10 14 V
OK
http://vnx.su
DI211
DIAGNOSTICS
Check voltage between terminals IG1 (14) and GND (6, 10) of ABS & BA & TRC &
VSC ECU.
ON
6
10
14
(+)
()
F12742
PREPARATION:
Disconnect the connector from the ABS & BA & TRC & VSC
ECU.
CHECK:
(b) Measure the voltage between terminals 14 and 6, 10 of
ABS & BA & TRC & VSC ECU harness side connector.
OK:
Voltage: 10 14 V
OK
NG
Check continuity between terminals GND (6, 10) of ABS & BA & TRC & VSC ECU
and body ground.
6
LOCK
()
CHECK:
Measure the resistance between terminal 6, 10 of ABS & BA &
TRC & VSC ECU harness side connector and body ground.
OK:
10
(+)
F12743
NG
OK
Check for open circuit in harness and connector between ABS & BA & TRC & VSC ECU and ECU
IG fuse (See page IN30).
http://vnx.su
DI212
DIAGNOSTICS

DI7ZT01
DTC
C1246 / 53
Master Cylinder Pressure Sensor Circuit
CIRCUIT DESCRIPTION
DTC No.
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 than 4.75 V).
2. The sensor supply voltage is out of range (above 5.6 V,
below 4.4 V).
3. The sensor signal offset value is out of range.
4. Stop light fuse is open.
Trouble Area
S Master cylinder pressure sensor

S Master cylinder pressure sensor circuit
S Stop light FUSE
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
O3 Oil Pressure Sensor

1
LY
LY
27
A29 VCM
LG
LG
11
A29 PMC
BR
BR
12
A29 E2
F13396
http://vnx.su
DI213
DIAGNOSTICS
HINT:
Start the inspection from step 1, in case of using the handheld tester and start from step 2, in case of not
Check the stop light FUSE and stop light bulb.
NG
Check the stop light switch circuit (See Pub. No.

RM599E on page BE45)
OK
Check output value of the master cylinder pressure sensor.
PREPARATION:
(c) Select the DATALIST mode on the handheld tester.
CHECK:
Check that the brake fluid pressure value of the master cylinder pressure sensor displayed on the handheld
tester is changing when depressing the brake pedal.
OK:
Brake fluid pressure value must be changing.
OK
Go to step 4.
NG
Check for open and short circuit in harness and connector between master cylinder pressure sensor and ABS & BA & TRC & VSC ECU (See page IN30).
NG
OK
http://vnx.su
DI214
DIAGNOSTICS
Check whether or not the ECU terminal STP input voltage is changed when the
stop light switch is turned on and off.
NO
Check the stop light switch circuit (See Pub. No.

RM599E on page BE45).
YES

ECU with actuator.
http://vnx.su
DI215
DIAGNOSTICS

DI7ZU01
DTC
C1249 / 58
CIRCUIT DESCRIPTION
DTC No.
Trouble Area
C1249 / 58
After the ignition switch is turned ON, the condition that the
STP terminal voltage of ECU is 55 % to 75 % of supplied
voltage, continues for 1 sec. or more.
S Stop light switch

S Stop light blub
WIRING DIAGRAM
Sedan:

STOP 10A 10
1
IA
IG
WR *5
W *6
Stop Light
Switch
W
GW
1
Center J/B
21
3F
ABS & BA & TRC&

VSC ECU
21
3D
GW
37
A29 STP
8 3C
1 F17
Fusible
Link
Block
ALT
120A
GW
6
5
ID1 II1
*5 *6
GW
F *1 F *1
1 F15
GW
J/C
BG
FL
Main
3.0W
2
Battery
D *2 D *2 GW
GW
6
2
Stop
Stop Light
Light LH
RH
4 WB
WB 4
A *4 A *4
A *4
High
Mounted
Stop
Light
J/C
A *3
WB
*3
WB
WB
BL *5
BN *6
*1: J12(LHD), J28(RHD)

*2: J13(LHD), J29(RHD)
*3: J10 (LHD), J30 (RHD)
*4: J11 (LHD), J31 (RHD)
*5: LHD
*6: RHD
BM
F13602
http://vnx.su
DI216
DIAGNOSTICS
Lift Back (LHD):

Stop Light
Switch

STOP 10A 10
1
IA
IG
WR
GW
6
ID1
GW
21
3D
GW
37
A29 STP
GW
D J14 D J14
1 BD1
J/C
BG
F J15 F J15
GW
FL
Main
3.0W
21
3F
GW
8 3C
1
Fusible F17
Link
Block
ALT 120A
1 F15
Center J/B
W
2
ABS & BA & TRC &

VSC ECU
High
Mounted
Stop
Light
1
2
GW
GW
3
Stop
Stop Light
Light RH
LH
3
5 WB
WB
E J15
E J15 B J15
WB
J/C
Battery
E J14
WB
E J14 B J14
WB
WB
BO
BQ
BP
ABS & BA & TRC &

VSC ECU
Lift Back (RHD):

Stop Light
Switch

STOP 10A 10
1
IA
IG
W
2
Fusible
Link
ALT 120A
Block
1 BD1
1 F15
BG
GW
1
2
Battery
GW
37
A29 STP
8 3C
5
II1
GW
21
3D
GW
E J33 D J32
J/C
GW
FL
Main
3.0W
21
3F
GW
W
1 F17
Center J/B
E J33
High
Mounted
Stop
Light
WB
BQ
E J33
GW
3
Stop
Light LH
5
WB
BP
GW
5
Stop Light
RH
3
WB
BO
F13603
http://vnx.su
DI217
DIAGNOSTICS
Wagon:
1
IA
WR *1
W *2
STOP 10A 10
IG
1 F17
Fusible
Link
ALT 120A
Block
GW
2
J16 *1
J34 *2
6
5
ID1 II1
*1 *2
GW
B
21
3F
21
3D
GW
37
A29 STP
8 3C
GW
J17 *1
J35 *2
1 F15
BG
ABS &BA & TRC &

VSC ECU
Stop Light
Switch
C
FL GW
Main
1
3.0W
C
High
Mounted
Stop
Light
2
A WB
C
GW
2
GW
Stop
Light LH
4 WB
A
Battery
A WB
Stop Light
RH
4 WB
A
J17 *1
J35 *2
J/C
A WB
BS
*1:LHD
*2:RHD
BR
F13604
1
CHECK:
Check that the stop light lights up when the brake pedal is depressed and turns off when the brake pedal
is released.
NG
Repair stop light circuit (See Pub. No. RM599E

on page BE45).
OK
http://vnx.su
DI218
DIAGNOSTICS
Check voltage between terminal STP (37) of ABS & BA & TRC & VSC ECU and
body ground.
37
F12745
PREPARATION:
ECU.
CHECK:
Measure the voltage between terminal 37 of ABS & BA & TRC
& VSC ECU harness side connector and body ground when the
brake pedal is depressed.
OK:
Voltage: 7.5 14 V
OK
NG
Check for open circuit in harness and connector between terminal STP of ABS &
BA & TRC & VSC ECU and stop light switch (See page IN30).
NG
OK
Proceed to next circuit inspection shown in problem symptoms table (See page DI181).
http://vnx.su
DI219
DIAGNOSTICS

DI7ZV01
DTC
C1288 / 88
ECU Version Miss Match
CIRCUIT DESCRIPTION
DTC No.
C1288 / 88
Trouble Area
When any of the following 1, through 2, is detecte:

1, Engine ECU (M/T) or Engine and ECT ECU (A/T) does
not match.
2, Steering angle sensor is not calibration.

S Engine ECU (M/T) or Engine and ECT ECU (A/T)
S Steering angle sensor calibration.
1
Check the steering angle sensor calibration.
NG
Steering angle sensor calibration (See page

DI171).
OK

http://vnx.su
DI220
DIAGNOSTICS

DI7ZW02
DTC
C1300 / 62
ABS & BA & TRC & VSC ECU Malfunction
CIRCUIT DESCRIPTION
DTC No.
C1300 / 62
Trouble Area
ABS & BA & TRC & VSC ECU internal malfunction is detected.
ABS & BA & TRC & VSC ECU
1
Check the DTC for the ABS and VSC (See page DI171).
*1
Repair ABS and VSC control system according

to the code output.
*2
Check for ECU is connected to malfunction

indicator light.
*1: Output NG code
*2: Malfunction indicator light remains ON
http://vnx.su
DI221
DIAGNOSTICS

DI7ZX01
DTC
C1350 / 51
Brake Actuator Pump Motor Failure
CIRCUIT DESCRIPTION
DTC No.
Trouble Area
C1350 / 51
When any of the following 1. through 3. is detected.

1. No motor voltage supply after ABS & BA & TRC & VSC
ECU of the motor relay.
2. A high level of motor voltage with no ABS & BA & TRC
& VSC ECU of the motor relay.
3. The pump motor voltage is high level for a certain time
after the motor relay has elapsed.
S Brake actuator pump motor

S Brake actuator pump motor circuit
1
PREPARATION:
(c) Turn the ignition switch ON.
CHECK:
Vehicle speed is more than 6 km/h (4 mph), and check if the same DTC is stored in the memory.
NO
No problem.
YES

http://vnx.su
DI222
DIAGNOSTICS

DI7ZY01
DTC
C1352 / 42
CAN Communication System Malfunction
CIRCUIT DESCRIPTION
The circuit is used to send TRC & VSC control information from yaw rate sensor and steering angle sensor
information to ABS & BA & TRC & VSC ECU
DTC No.
C1352 / 42

IG1 voltage is 9.5 V or more, and the condition that data
from ECU can not be received continues for 1.2 sec. or
more.
Trouble Area
http://vnx.su
DI223
DIAGNOSTICS
WIRING DIAGRAM
Steering Sensor
(Shielded)
6
LGR
12V S23
5
BRW
GND S23
7
CAN
HIGH
CAN
LOW
S23
1
S23
ABS & BA & TRC

& VSC ECU
Yaw Rate Sensor

4
UBAT Y1
LGR
2
GND Y1
BRW
LGR
30
A29 YIGA
16
A29 YGND
BRW
(Shielded)
(LHD)
(Shielded)
3
CANH Y1
13
A29 SS1
1
CANL Y1
29
A29 SS2
(Shielded)
(LHD)
Center J/B
WB
Center J/B
13
3A
3F
WB
9
3F
9
3E
WB Instrument Panel J/B

4
IE
11
IH
WB
*1: IH (LHD)
IK (RHD)
*1
F13397
http://vnx.su
DI224
DIAGNOSTICS
1
Check for open and short circuit in harness and connector between each of terminals CANLOW and CANHIGH of steering angle sensor, CANL and CANH of
yaw rate sensor and ABS & BA & TRC & VSC ECU (See page IN30).
NG
OK

http://vnx.su
DI225
DIAGNOSTICS

DI7ZZ01
DTC
Always ON
Malfunction in ECU
ABS Warning Light Circuit
CIRCUIT DESCRIPTION
DTC No.
Always ON
Trouble Area
Either of the following 1., 2. or 3. is detected:

1. The ECU connectors are OFF the ECU.
2. There is a malfunction in the ECU internal circuit.
3. There is a malfunction in ABS warning light circuit.
S Charging system
S ABS warning light circuit
HINT:
Handheld tester may not be able to be used when the ECU is defective.
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
Combination Meter
Center J/B
10
3A
RL
10
3F
RL
9
C11
1
3F
RL
22
C11
10
C11
10
IF
Ignition SW
5
IC
BY
8
IG1
W(RHD)
W(LHD)
1 F17
35
A29 WA
ABS

GAUGE 10A
PL
AM1

AM1 40A
2
3
1
2
IA
IC
2 F17
Fusible
Link
Block
ALT 120A
1 F15
BG
FL Main
3.0W
Battery
F13398
http://vnx.su
DI226
DIAGNOSTICS
1
Check that the ECU connectors are securely connected to the ECU.
NO
Connect the connector to the ECU.
YES
Repair circuit indicated by the output code .
YES
Is DTC output?
NO
Check for open or short circuit in harness and connector between combination meter
and ABS & BA & TRC & VSC ECU (WA).
NG
OK
http://vnx.su
DI227
DIAGNOSTICS
Check voltage between terminals IG1 (14) and GND (6,10)or ABS & BA & TRC &
VSC ECU.
ON
6
10
14
(+)
()
F12742
PREPARATION:
ECU.
CHECK:
(b) Measure the voltage between terminals 14 and 6, 10 of
ABS & BA & TRC & VSC ECU harness side connector.
OK:
Voltage: 10 14 V
OK
NG
http://vnx.su
DI228
DIAGNOSTICS

DI80001
DTC
Always ON
Malfunction in ECU
VSC Warning Light Circuit
CIRCUIT DESCRIPTION
DTC No.
Always ON
Trouble Area
Either of the following 1. or 2. is detected:

1. There is a malfunction in the ECU internal circuit.
2. There is a malfunction in VSC warning light circuit.
S Charging system
S VSC warning light circuit
HINT:
Handheld tester may not be able to be used when ECU is defective.
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
Combination Meter
Center J/B
10
3A
RL
10
3F
RL
9
C11
1
3F
RL
22
C11

GAUGE 10A 5
10
IC
IF
23
C10
W(LHD)
1 F17
34
A29 VSCW
VSC
Ignition SW
BY
8
IG1
W(RHD)
AM1

AM1 40A
2
3
1
2
IA
IC
2 F17
Fusible
Link
Block
ALT 120A
1 F15
BG
FL Main
3.0W
Battery
F13398
http://vnx.su
DI229
DIAGNOSTICS
1
Does both VSC warning light and VSC OFF indicator light go on?
YES
Go to step 4.
YES
NO
Is DTC output?
NO
Check for open or short circuit in harness and connector between combination mater
and ABS & BA & TRC & VSC ECU (WT).
OK
YES
NG
Is DTC output?
NO
http://vnx.su
DI230
DIAGNOSTICS
Check the steering angle sensor calibration.
NO
Calibrate the steering angle sensor (See page

DI171).
OK

http://vnx.su
DI231
DIAGNOSTICS

DI80101
ABS Warning Light Circuit (Does Not Light Up)

WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
Combination Meter
Center J/B
10
3A
RL
10
3F
RL
9
C11
1
3F
RL
22
C11

GAUGE 10A 5
10
IC
IF
10
C11
W(LHD)
1 F17
35
A29 WA
ABS
Ignition SW
BY
8
IG1
W(RHD)
PL
AM1

AM1 40A
2
3
1
2
IA
IC
2 F17
Fusible
Link
Block
ALT 120A
1 F15
BG
FL Main
3.0W
Battery
F13398
http://vnx.su
DI232
DIAGNOSTICS
HINT:
Start the inspection from step 1 in case of using a handheld tester and start from step 2 in case of not using
the handheld tester.
Check operation of the ABS warning light.
PREPARATION:
(c) Select the ACTIVE TEST mode on the handheld tester.
CHECK:
Check that ON and OFF of the ABS warning light can be shown on the combination meter on the hand
held tester.
OK

NG
Check ABS warning light.
NG
Replace or repair bulb or combination meter.
OK
Repair or replace and check for open or short circuit in harness and connector.
http://vnx.su
DI233
DIAGNOSTICS

DI80201
VSC Warning Light Circuit (Does Not Light Up)

CIRCUIT DESCRIPTION
If the ECU stores DTC to be necessary to shut down VSC operation, the VSC warning light lights on the
combination meter.
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
Combination Meter
Center J/B
10
3A
RL
10
3F
RL
9
C11
1
3F
RL
22
C11

GAUGE 10A 5
10
IC
IF
23
C10
W(LHD)
1 F17
34
A29 VSCW
VSC
Ignition SW
BY
8
IG1
W(RHD)
AM1

AM1 40A
2
3
1
2
IA
IC
2 F17
Fusible
Link
Block
ALT 120A
1 F15
BG
FL Main
3.0W
Battery
F13398
http://vnx.su
DI234
DIAGNOSTICS
HINT:
Check operation of the VSC warning light.
PREPARATION:
CHECK:
Check that ON and OFF of the VSC warning light can be shown on the combination meter with the hand
held tester.
OK
with astuator assembly.
YES
NG
Is DTC output?
NO
Check for open and short circuit in harness and connector between ABS & BA &
TRC & VSC ECU and VSC warning light (See page IN30).
NG
OK
http://vnx.su
DI235
DIAGNOSTICS
Check VSC warning light.
See the combination meter troubleshooting (See Pub. No. RM599E on page BE57).
NG
Repair or replace bulb or combination meter.
OK

ECU with actuator aseembly.
http://vnx.su
DI236
DIAGNOSTICS

DI80301
BRAKE Warning Light Circuit

CIRCUIT DESCRIPTION
The BRAKE warning light lights up when the brake fluid is insufficient, when the parking brake is applied or
when the EBD is defective.
http://vnx.su
DI237
DIAGNOSTICS
WIRING DIAGRAM
Center J/B
10
3A
10
3F
1
3F
EBD
Resistor
BR
1
RL
ABS & BA &

TRC & VSC ECU
Combination
Meter
RL
9
C11
RL
22
C11
RW
RW
2
RW
C11
RW
20
A29 EBDW
RW
31
A29 PKB
BRAKE
2
2
IC3 IF4
(LHD) (RHD)
Center J/B
18
3G
18
3A
BR
ECUIG 5A
9
IE
5
IC
10
IF
BY
GAUGE 10A
AM1 40A
3
2
2
1
IA
IC
W (RHD)
Ignition SW
W
5
AM1
IG1
W (LHD)
1 F17
2 F17
ALT 120A
Fusible
Link
Block
1 F15
BG
Parking
Brake
SW
FL Main
3.0W
Battery
F13399
http://vnx.su
DI238
DIAGNOSTICS
1
Check parking brake switch circuit (See Pub. No. RM599E on page BE57).
NG
Repair or replace parking brake switch circuit.
OK
Check brake fluid level warning switch circuit (See Pub. No. RM599E on page
BE57).
NG
Repair or replace brake fluid level warning

switch circuit.
YES
OK
Is DTC output for ABS ?
No
Check BRAKE warning light.
NG
OK
http://vnx.su
DI239
DIAGNOSTICS
Check for open or short circuit in harness and connector between combination
meter and ABS & BA & TRC & VSC ECU (See page IN30).
NG
OK

http://vnx.su
DI240
DIAGNOSTICS

DI80401
SLIP Indicator Light Circuit

CIRCUIT DESCRIPTION
The SLIP indicator light blinks during TRC & VSC operation.
WIRING DIAGRAM
ABS & BA &

TRC & VSC ECU
Combination Meter
Center J/B
10
3A
RL
10
3F
RL
9
C11
1
3F
RL
22
C11

GAUGE 10A 5
10
IC
IF
25
C10
W(LHD)
1 F17
4
A29 IND
SLIP
Ignition SW
BY
8
IG1
W(RHD)
AM1

AM1 40A
2
3
1
2
IA
IC
2 F17
Fusible
Link
Block
ALT 120A
1 F15
BG
FL Main
3.0W
Battery
F13398
http://vnx.su
DI241
DIAGNOSTICS
HINT:
Start the inspection from step 1, in case of using the handheld tester and start from step 2, in case of not
Check operation of the SLIP indicator light.
PREPARATION:
CHECK:
Check that ON and OFF of the SLIP indicator light can be shown on the combination meter with the hand
held tester.
OK
Go to step 4.
NG
Check that the SLIP indicator light is ON for 3 seconds immediately after ignition
switch is turned ON.
OK

NG
Check SLIP indicator light.
NG

OK
http://vnx.su
DI242
DIAGNOSTICS
Check for open and short circuit in harness and connector between ABS & BA
TRC & VSC ECU and SLIP indicator light (See page IN30).
NG
OK

http://vnx.su
DI243
DIAGNOSTICS

DI80501
VSC OFF Indicator Light, VSC OFF Switch Circuit

CIRCUIT DESCRIPTION
This is the TRC & VSC control main switch. When the VSC OFF switch is pressed, TRC & VSC control is
deactivated and the VSC OFF indicator light lights up. By turning off the ignition switch, TRC & VSC control
is surely activated when the ignition switch turns ON next time. Also, the VSC OFF indicator light truns ON
when the ECU prohibit TRC & VSC controls.
http://vnx.su
DI244
DIAGNOSTICS
WIRING DIAGRAM
Center J/B
10
3A
RL

GAUGE 10A 5
10
BY
IF
IC
Ignition SW
W
5
AM1
IG1

AM1 40A
3
2
2
1
IA
IC
ABS & BA &

TRC & VSC ECU
Combination
Meter
10
3F
RL
1
3F
RL
20
C11
C10
22
C11
VSC
Off
GW
(LHD)
VSC Off SW
6
WB
(LHD)
9 GR
(RHD)
Center J/B
WB
(RHD)
7
IM1
22
3E
9
3F
13
3H
4
3F
GR
(RHD)
42
A29 CSW
WB
13
3A
W (RHD)
W (LHD)
1 F17
2
A29 WT
WB
4
IE
11
IH
2 F17
ALT 120A
Fusible
Link
Block
WB
1 F15
BG
FL Main
3.0W
Battery
*1
*1: IH (LHD)
IK (RHD)
F13400
http://vnx.su
DI245
DIAGNOSTICS
HINT:
Check operation of the VSC OFF indicator light.
PREPARATION:
CHECK:
Check that ON and OFF of the VSC OFF indicator light can be shown on the combination meter with the
handheld tester.
NG
Go to step 4.
OK
Check VSC OFF switch.
PREPARATION:
(a) Remove the VSC OFF switch.
(b) Disconnect the VSC OFF switch connector.
CHECK:
Measure the resistance between terminals 1 and 4 of the VSC
OFF switch when the VSC OFF switch is ON and OFF.
OK:
(+)
()
F00052
NG
VSC OFF switch
Resistance
Pressed
Continuity
Released
1M or higher
Replace VSC OFF switch.
OK
http://vnx.su
DI246
DIAGNOSTICS
Check for open and short circuit in harness and connector between terminal
CSW of ABS & BA & TRC & VSC ECU and VSC OFF switch and body ground (See
page IN30).
NG
OK
Check VSC OFF indicator light.
NG
OK
Check for open and short circuit in harness and connector between terminal WT
of ABS & BA & TRC & VSC ECU and VSC OFF indicator light (See page
IN30).
NG
OK

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DI247
DIAGNOSTICS

DI80601
VSC Buzzer Circuit

CIRCUIT DESCRIPTION
The VSC buzzer sounds during VSC operation.
WIRING DIAGRAM
VSC Warning
Buzzer
Center J/B
1
3B
10
3A
RL

GAUGE 10A 5
10
IF
IC
W (RHD)
W (LHD)
1 F17
ABS & BA &

TRC & VSC ECU
RL
Buzzer
15
A29 BZ
Ignition SW
BY
IG1
AM1
AM1 40A
3
2
2
1
IA
IC
2 F17
ALT 120A
Fusible
Link
Block
1 F15
BG
FL Main
3.0W
Battery
F13401
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DI248
DIAGNOSTICS
HINT:
Check operation of the VSC buzzer.
PREPARATION:
CHECK:
Check ONOFF function of the VSC buzzer with the handheld tester.
OK
NG
Check voltage between terminal 1 of VSC buzzer and body ground.
PREPARATION:
Disconnect the connector from VSC buzzer.
CHECK:
(b) Measure voltage between terminal (1) of VSC buzzer and body ground.
OK:
Voltage: 10 14 V
NG
Repair or replace harness or connector from

battery to VSC buzzer.
OK
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DI249
DIAGNOSTICS
Check VSC buzzer.

1
(+)
()
2
PREPARATION:
Disconnect the VSC buzzer connector.
CHECK:
Apply battery voltage to the terminals 1 and 2 of VSC buzzer
connector, and check that the VSC buzzer sounds.
F02192
NG
Replace VSC buzzer.
OK
TRC & VSC ECU and VSC buzzer (See page IN30).
NG
OK

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DI250
DIAGNOSTICS

DI80701
Tc Terminal Circuit
CIRCUIT DESCRIPTION
Connecting between terminals Tc and CG of the DLC3 causes the ECU to display DTC by blinking the ABS
warning light, VSC warning light and BRAKE warning light.
WIRING DIAGRAM
ABS & BA &
TRC & VSC ECU
D8
DLC3
4
CG
TC
13
LGR
J44
Junction
Connector
F
F
LGR
17
A29 TC
WB
Junction
Connector
J1 (LHD)
J27 (RHD)
*1
*1: II (LHD)
IJ (RHD)
F04476
1
Check voltage between terminals Tc and CG of DLC3.

CHECK:
(b) Measure voltage between terminals Tc and CG of DLC3.
OK:
Voltage: 10 14 V
ON
Tc
(+)
()
DLC3
CG
F09678
OK
If each warning light does not blink even after Tc

NG
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DI251
DIAGNOSTICS
TRC & VSC ECU and DLC3, DLC3 and body ground (See page IN30).
NG
OK

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DI252
DIAGNOSTICS

DI80801
Ts Terminal Circuit
CIRCUIT DESCRIPTION
The sensor check circuit detects abnormality in the speed sensor signal which cannot be detected with the
DTC check.
Connecting terminals Ts and CG of the DLC3 starts the check.
WIRING DIAGRAM
ABS & BA &
TRC & VSC ECU
D8
DLC3
4
CG
TS
14
RB
28
A29 TS
WB
Junction
Connector
J1(LHD)
J27(RHD)
*1: II(LHD)
IJ(RHD)
*1
F04477
1
ON
Check voltage between terminals Ts and CG of DLC3.
Tc
(+)
CHECK:
(b) Measure the voltage between terminals Ts and CG of
DLC3.
OK:
Voltage: 10 14 V
()
DLC3
CG
F09679
OK
If ABS warning light does not blink even after Ts

NG
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DI253
DIAGNOSTICS
TRC & VSC ECU and DLC3, DLC3 and body ground (See page IN30).
NG
OK

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DI254
DIAGNOSTICS

DI80901

Check for fluid leakage from actuator or hydraulic lines.
F04266
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DI255
DIAGNOSTICS

DI7FG03

Troubleshooting in accordance with the procedure on the following pages.
Items inside
with the page number in the bottom portion.
See the pages for detailed explanations.

P. DI256

P. DI257
Symptom
dose not occur
Symptom Simulation
P. IN20

P. DI263
Symptom
occurs
Normal code
DTC Check
P. DI257
Malfunction code
DTC Chart
P. DI259
Circuit Inspection and Part Inspection

P. DI264
9
10
Repair
Confirmation Test
Step 2, 5 : Diagnostic steps permitting the
use of the handheld tester
End
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DI256
DIAGNOSTICS

DI7FH01

ENGINE IMMOBLISER Check Sheet
Inspectors
:
Name
Registration No.
Registration Year
Customers Name
Frame No.
Date Vehicle
Brought In
km
miles
Odometer Reading
Continuous
/
Intermittent (
times a day)
Immobiliser is not set.

(Engine starts with key codes other than the registered key code.)
Symptoms
Engine does not start.
Check Item
Malfunction
Indicator Light
Normal
Remains ON
Does not Light Up
1st Time
Normal Code
2nd Time
Normal Code
DTC Check
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DI257
DIAGNOSTICS

DI7W602
Handheld Tester
PRECHECK
1.
(a)
DIAGNOSIS SYSTEM
Description
Engine ECU controls the function of immobiliser on this
vehicle.
Data of the immobiliser or Diagnostic Trouble Code (DTC)
can be read from the Data Link Connector 3 (DLC3) of the
vehicle. When a trouble occurs in immobiliser, Malfunction Indicator Lamp (MIL) does not light ON but DTC inspection is performed.
Therefore when there seems to be a trouble with immobiliser, use handheld tester or SST (diagnosis check wire
No. 2) to check and troubleshoot it.
(b)
Inspect the DLC3.

The vehicles engine ECU uses ISO 14230 for communication.
The terminal arrangement of the DLC3 complies with
SAE J1962 and matches the ISO 14230 format.
DLC3
D01600
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
DLC3
A04550
Tester connection
Condition
Specified condition
7 (Bus + Line) 5 (Signal Ground)
Pulse generation
4 (Chassis Ground) Body Ground
Always
1 or less
5 (Signal Ground) Body Ground
Always
1 or less
16 (B+) Body Ground
Always
9 14 V
HINT:
when you have connected the cable of the handheld tester to
the DLC3, turned the ignition switch ON and operated the
handheld tester, there is a problem on the vehicle side or tool
side.
S
S
If communication is still impossible when the tool is connected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tools instruction manual.
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DI258
DIAGNOSTICS
2.
(a)
INSPECT DIAGNOSIS
Using handheld tester:
Check the DTC.
NOTICE:
Handheld tester only:
When the diagnosis system is switched from the normal
mode to the check mode, it erases all DTCs and freezed
frame data recorded in the normal mode. So before switching the modes, always check the DTCs and freezed frame
data, and note them down.
(2)
Handheld Tester
DLC3
D01600
(b)
Connect the handheld tester to the DLC3 under

the instrument panel lower pad.
(3) Turn the ignition switch ON and push the handheld
tester switch ON.
(4) Use the handheld tester to check the DTCs and
freeze frame data; note them down. (For operating
instructions, see the handheld tester instruction
book.)
(5) See page DI259 to confirm the details of the DTCs.
Clear the DTC.
The following procedures will erase the DTCs and freeze
frame data.
(1) Operating the handheld tester to erase the codes.
(See the handheld tester instruction book for operating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
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DI259
DIAGNOSTICS

DI7FJ02

DTC No.
(See page)
B2795
(DI264)
B2796
(DI265)
B2797
(DI267)
B2798
(DI268)
Detection Item
Trouble Area
Unmatched Key Code
S Key
S Unregistered key inserted before
No Communication in Immobiliser System
S Key
S Transponder key amplifier
S Wire harness
S Engine ECU
Communication Malfunction No. 1
S Wire harness
S Engine ECU
S Key
S Wire harness
S Engine ECU
HINT:
To reduce the unnecessary exchange of engine ECU, check that a trouble occurs with the original engine
ECU at the time of exchanging engine ECU and the problem will be solved with a new engine ECU.
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DI260
DIAGNOSTICS

DI7FK03
PARTS LOCATION
Engine Room J/B
S EFI Fuse
S EFI Relay
Engine ECU
Transponder Key Amplifier
DLC3
Ignition Switch
I19380
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DI261
DIAGNOSTICS

DI80I01
TERMINALS OF ECU
1AZFSE Engine ECU Terminals
E16
E17
E14
E15
E13
D03442
D01054
Symbols (Terminal No.)
Wiring Color
Condition
STD Voltage (V)
CODE (E1314)
E1 (E163)
B BR
Ignition switch ON
9 14
RXCK E1313)
E1 (E163)
BO BR
Ignition switch ON
9 14
TXCT E1321)
E1 (E163)
BW BR
Ignition switch ON
9 14
1ZZFE (A/T) Engine and ECT ECU Terminals

E18
E19
E20
E21
9 8 7 6 5 4 3
2 1
2120 1918 17 16 15 1413 12 11 10
31 30 29 28 27 2625 24 23 22
7 6 5 4 3
2 1
16 1514 13 12 11 10 9 8
24 23 22 2120 1918 17
9 8 7
6 5 4 3 2 1
1918 17 16 1514 13 12 11 10
28 27 2625 24 23 22 2120
7 6
5 4 3 2 1
1514 13 12 11 10 9 8
22 21 20 1918 17 16
D05962
Wiring Color
Condition
CODE (E207)
E1 (E1917)
B BR
Ignition switch ON
9 14
RXCK (E2026)
E1 (E1917)
BO BR
Ignition switch ON
9 14
TXCT(E2015)
E1 (E1917)
BW BR
Ignition switch ON
9 14
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STD Voltage (V)
DI262
DIAGNOSTICS
1ZZFE (M/T) and 3ZZFE Engine ECU Terminals

E18
E20
E19
D00032
Wiring Color
Condition
CODE (E2019)
E1 (E1814)
B BR
Ignition switch ON
9 14
RXCK (E2020)
E1 (E1814)
BO BR
Ignition switch ON
9 14
TXCT(E2018)
E1 (E1814)
BW BR
Ignition switch ON
9 14
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STD Voltage (V)
DI263
DIAGNOSTICS

DI7FM02

Symptom
Suspected Area
See page
Immobiliser is not set

(Engine starts with key codes other than the registered key code)
1. Engine ECU
IN30
Engine does not start
1.
2.
3.
4.
L
IN30
IN30
Key
Wire harness
Transponder key amplifier
Engine ECU
L: Check that the key which did not start the engine has been registered and that it is possible to start with
other already registered key codes.
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DI264
DIAGNOSTICS

DI7FN01
CIRCUIT INSPECTION
DTC
B2795
Unmatched Key Code
CIRCUIT DESCRIPTION
This DTC is output when an unregistered key is inserted. When this DTC is output, delete DTC and insert
the key of the customer to check that DTC B2795 is output.
When the key that outputs DTC B2795, register this key. When DTC B2795 is not output, there is a possibility
that the unregistered key has been inserted before. (Engine ECU is normal.)
Inquire of a customer the condition of using the system to find the cause of the trouble.
(Example: Another key has been inserted, etc.)
DTC No.
B2795
Trouble Area
S Key
Unmatched key code
1
Delete DTC and insert all presently available keys to check whether engine starts
or not.
HINT:
When inserting the key that does not start the engine, DTC B2795 is stored in memory.
RESULT:
OK
All keys starts engine.
NG
A specific key does not start engine.
OK
No problem.
HINT:
If the result is OK, please confirm whether or not customers
have ever inserted the unregistered key or the immobiliser key
(with transponder chip) of other vehicle in the ignition key cylinder, and find out the cause of detecting DTC.
NG
Register key that does not start engine.
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DI265
DIAGNOSTICS

DI7FO03
DTC
B2796
No Communication in Immobiliser system
CIRCUIT DESCRIPTION
DTC No.
B2796
Trouble Area
S Key
S Wire harness
S Engine ECU
No communication
WIRING DIAGRAM
Transponder Key Amplifier
CODE
Engine ECU
14 19 7
E13 E20 E20 CODE
*1
RXCK
BO
TXCT
BW
*3
13 20 26
E13 E20 E20 RXCK
*1
*2
*2
*3
21 18 15
E13 E20 E20 TXCT
*1
*2
*3
*1: 1AZ FSE

*2: 1ZZFE (M/T), 3ZZFE
*3: 1ZZFE (A/T)
I19381
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DI266
DIAGNOSTICS
1
Delete DTC and insert all presently available keys to check whether engine starts
or not
RESULT:
A
All keys start engine.
A specific key does not start engine. In this case, DTC B2796 is stored in memory.
All keys do not start engine. In this case, DTC B2796 is stored in memory.
No problem at this time.
HINT:
If the result is A, please confirm whether or not customers
have ever inserted the key (without transponder chip) of other
vehicle in the ignition key cylinder, and find out the cause of detecting DTC.
B
Transponder chip of a specific key is defective.

Replace key.
Check harness and connector between transponder key amplifier and engine
NG
OK
Does it operate normally after replacement of transponder key amplifier ?
Yes
Replace transponder key amplifier.
No
Check and replace engine ECU

(See page IN30).
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DI267
DIAGNOSTICS

DI7FP03
DTC
B2797
CIRCUIT DESCRIPTION
This code is detected when an error occurs despite of normal communication.
(Example: Some noise is included in communication line.)
DTC No.
B2797
Trouble Area
S Wire harness
S Engine ECU
Communication error
WIRING DIAGRAM
Refer to DTC B2796 on page DI265.
1
Check noise.
PREPARATION:
Insert already registered master key in the key cylinder.
CHECK:
Using an oscilloscope or handheld tester, check that noise is
included in the CODE terminal of the engine ECU.
OK:
No noise is detected.
Noise
I02681
NG
Try to find cause of noise and remove it.
OK
Does it operate normally after replacement of transponder key amplifier?
Yes
No

(See page IN30).
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DI268
DIAGNOSTICS

DI7FQ02
DTC
B2798
CIRCUIT DESCRIPTION
DTC No.
B2798
Trouble Area
S Key
S Wire harness
S Engine ECU
Communication error
WIRING DIAGRAM
Refer to DTC B2796 on page DI265.
1
Check harness and connector between transponder key amplifier and engine
NG
OK
Does it operate normally after replacement of transponder key amplifier?
Yes
No

(See page IN30).
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DI269
DIAGNOSTICS

DI7FR03
Power Source Circuit

CIRCUIT DESCRIPTION
This circuit provides power to operate the transponder key amplifier.
WIRING DIAGRAM
W
(*4)
1
2H
W
(*3)
Engine Room J/B

EFI Relay
EFI
5
3
4
2B
Transponder
Key Amplifier
6
2B
LY
1
3
2F
1
2F
E/G
BAT
WB
WB
BG
Center J/B
From
Terminal
MREL
of
Engine
ECU
13
3A
WB
IE 4
FL
MAIN
10
GND
*1: LHD
*2: RHD
*3: 1AZFE
*4: 1ZZFE, 3ZZFE
WB
WB
WB
Instrument Panel
J/B
IH 11
WB
13
3F
WB
Battery
IH *1
IK *2
EA
EB
I20881
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DI270
DIAGNOSTICS
1
Check voltage between terminals +B and GND of transponder key amplifier connector.
(+)
PREPARATION:
(a) Turn the ignition switch OFF.
(b) Disconnect the transponder key amplifier connector.
CHECK:
Measure the voltage between terminals +B and GND of the
transponder key amplifier connector.
OK:
Voltage: 9 14 V
10
()
I20882
OK

NG
Check EFI fuse.
Engine Room J/B
PREPARATION:
Remove the EFI fuse from the engine room J/B.
CHECK:
Check the continuity of the EFI fuse.
OK:
Continuity
EFI Fuse
NG
A05531
Check for short in all harness and components

connected to EFI fuse.
OK
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DI271
DIAGNOSTICS
Check harness and connector between transponder key amplifier and body
ground (See page IN30).
NG
OK
Check and repair harness and connector between transponder key amplifier and battery
(See page IN30).
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CLUTCH
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER . . . . . . . . . . . .
CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
CL1
CL3
CL9
REFER TO AVENSIS/CORONA REPAIR MANUAL FOR

CHASSIS AND BODY (Pub. No. RM599E)
from the above listed manual.
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CL1
CLUTCH
CLUTCH PEDAL
CLUTCH PEDAL
Push Rod Play and

Freeplay Adjust Point
CL01505
INSPECTION
1.
Pedal Height
Adjust Point
Push Rod Play
Pedal Height
D02446
CHECK PEDAL HEIGHT

Pedal height from asphalt sheet:
LHD:
1ZZFE Engine:
139.7 149.7 mm (5.500 5.894 in.)
3ZZFE Engine:
139.7 149.7 mm (5.500 5.894 in.)
1AZFSE Engine:
148.3 158.3 mm (5.839 6.232 in.)
RHD:
1ZZFE Engine:
144.3 154.3 mm (5.681 6.075 in.)
3ZZFE Engine:
144.3 154.3 mm (5.681 6.075 in.)
1AZFSE Engine:
152.9 162.9 mm (6.010 6.413 in.)
2.
IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3.
CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Depress pedal until clutch resistance begins to be felt.
Pedal freeplay:
1.0 5.0 mm (0.039 0.197 in.)
Gently push on the pedal until the resistance begins to increase
a little.
Push rod play at pedal top:
5.0 15.0 mm (0.197 0.591 in.)
4.
(a)
(b)
Pedal Freeplay
CL0102
(c)
(d)
(e)
IF NECESSARY, ADJUST PEDAL FREEPLAY AND

PUSH ROD PLAY
Remove the air duct and the lower finish panel
(See page BO8).
Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct.
Tighten the lock nut.
After adjusting the pedal freeplay, check the pedal height.
Connect the air duct and install the lower finish panel.
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CL2
CLUTCH
25 mm (0.98 in) or more

Release
Point
Full Stroke
End Position
CL0512
CLUTCH PEDAL
5.
(a)
(b)
(c)
CHECK CLUTCH RELEASE POINT

Pull the parking brake lever and install wheel stopper.
Start the engine and idle the engine.
Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears make contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops (release point) to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following operations.
S
Inspect pedal height.
S
Inspect push rod play and pedal freeplay.
S
Bleed the clutch line.
S
Inspect the clutch cover and disc.
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CL3
CLUTCH
CLUTCH MASTER CYLINDER

CL01603
COMPONENTS
LHD:
Lock Nut
Filler Cap
Clevis
Boot
Snap Ring
Reservoir Tank
Clip
Push Rod
Reservoir Hose
12 (120, 9)
Clip
Pin
Piston
Spring
Clip
1CDFTV Engine LHD:
w/ Damper:
Inlet Union
ORing
Washer
Clutch Line
15 (155, 11)
Master Cylinder
Body
Clevis
1ZZFE, 3ZZFE, 1AZFSE Engine RHD:
Filler Cap
Lock Nut
Float
Snap Ring
Washer
Reservoir Tank
Pin
Push Rod
zGrommet
12 (120, 9)
Slotted Spring Pin
Clevis
Piston
Spring
Clip
Boot
Clutch Line
z Nonreusable part
15 (155, 11)
D02178
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CL4
CLUTCH
1CDFTV Engine RHD:
Filler Cap
Float
Clevis
Reservoir Tank
Snap Ring
Clip
Push Rod
12 (120, 9)
Pin
Piston
zGrommet
Spring
Slotted Spring
Pin
Lock Nut
Boot
Washer
Clutch Line
Master Cylinder
Body
15 (155, 11)
z Gasket
Clutch Accumulator
For use with SST: 32 (330, 24)
For use without SST: 44 (450, 33)

z Nonreusable part
D02437
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CL5
CLUTCH

CL01707
REMOVAL
1.
DRAW OUT FLUID WITH SYRINGE
2.
LHD:
DISCONNECT RESERVOIR TANK
Disconnect reservoir tank from reservoir tank bracket.
D02438
3.
LHD:
SST
RHD:
SST
LHD:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line. Use a container to catch
the fluid.
SST 0902300100, 0924963010
4.
RHD:
DISCONNECT CLUTCH LINE
Using SST, disconnect the clutch line. Use a container to catch
the fluid.
SST 0902300100
5.
REMOVE CLIP AND PIN
6.
REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER AND GASKET
D02439
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CL6
CLUTCH

CL05102
DISASSEMBLY
1.
Yellow Mark
White Mark
(a)
(b)
(c)
LHD:
REMOVE RESERVOIR TANK
Using a pliers, disconnect the 2 clips.
Remove the reservoir tank from reservoir hose.
Remove the reservoir hose from inlet union.
(d)
Remove the inlet union.
2.
RHD:
REMOVE RESERVOIR TANK
spring pin.
Remove the reservoir tank and grommet.
D02444
D02445
(a)
(b)
D02440
3.
(a)
(b)
(c)
REMOVE PUSH ROD

Pull back the boot and remove the snap ring with snap
ring pliers.
Pull out the push rod and washer.
Remove the piston from the cylinder.
D00277
4.
1CDFTV ENGINE RHD:

REMOVE CLUTCH ACCUMULATOR
Using SST, remove the accumulator and gasket.
SST 0992210010
SST
D00279
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CL7
CLUTCH

CL05203
REASSEMBLY
SST
1.
Fulcrum
Length
D00280
1CDFTV ENGINE RHD:

INSTALL CLUTCH ACCUMULATOR
Using SST, install the accumulator with a new gasket.
SST 0992210010
Torque:
For use with SST:
32 Nm (330 kgfcm, 24 ftlbf)
For use without SST
44 Nm (450 kgfcm, 33 ftlbf)
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
2.
3.
4.
COAT PARTS WITH LITHIUM SOAP BASE GLYCOL

GREASE, AS SHOWN IN ILLUSTRATION
INSERT PISTON INTO CYLINDER
INSTALL PUSH ROD ASSEMBLY WITH NEW GASKET
AND NEW PISTON STOP PLATE
CL0528
5.
(a)
(b)
Yellow Mark
(c)
White Mark
(d)
LHD:
INSTALL RESERVOIR TANK
Install the Oring and inlet union.
Facing the white mark upwards, install the reservoir hose
to the reservoir tank.
Facing the yellow mark upwards, install the reservoir hose
to the cylinder.
Using a pliers, connect the 2 clips.
D02444
6.
(a)
(b)
Protrusion
1.5 3.5 mm
(0.059 0.138 in.)
RHD:
INSTALL RESERVOIR TANK
Install the reservoir tank and a new grommet.
pin.
D02441
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CL8
CLUTCH

CL01A02
INSTALLATION
Installation is in the reverse order of removal (See page CL5).
HINT:
After installation, bleed the clutch system and adjust the clutch pedal.
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CL9
CLUTCH
CLUTCH UNIT
CLUTCH UNIT
CL01J04
COMPONENTS
19 (195, 14)
Release Bearing
x6
Clip
Release Fork Support

*1: 37 (375, 27)
*2: 39 (400, 29)
Flywheel
Clutch Disc
Clutch Cover
Release Fork
Boot
*1: 1ZZFE, 3ZZFE Engine

*2: 1CDFTV Engine
D00201
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CL10
CLUTCH
CLUTCH UNIT
CL01K04
REMOVAL
1.
REMOVE TRANSAXLE FROM ENGINE

C50, C250 M/T: See page MX2
S54, S55 M/T: See page MX2
E351 M/T: See page MX2
2.
(a)
(b)
Matchmarks
REMOVE CLUTCH COVER AND DISC

Place matchmarks on the flywheel and clutch cover.
Loosen each set bolt one turn at a time until spring tension
is released.
(c) Remove the set bolts, and pull off the clutch cover with the
clutch disc.
NOTICE:
Do not drop the clutch disc.
D00202
3.
REMOVE RELEASE BEARING AND FORK FROM

TRANSAXLE
Remove the release bearing with the fork together and then
separate them.
Q01056
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CL11
CLUTCH
CLUTCH UNIT
CL01L04
INSPECTION
1.
INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth:
0.3 mm (0.012in.)
If necessary, replace the clutch disc.
Q01057
2.
INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc.
Maximum runout:
0.8 mm (0.031 in.)
If necessary, replace the clutch disc runout.
Q06033
3.
INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout:
0.1 mm (0.004 in.)
If necessary, replace the flywheel.
D00203
4.
INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum runout:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
If necessary, replace the clutch cover.
B
A
Z10408
5.
INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direction.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.
Q01060
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CL12
CLUTCH
CLUTCH UNIT
CL01M04
INSTALLATION
SST
1.
Flywheel Side
(a)
D00682
SST
HINT:
Take care not to insert clutch disc in the wrong direction.
(b) Others:
Insert SST in the clutch disc, and then insert them in the
flywheel.
SST 0930100120
HINT:
Take care not to insert clutch disc in the wrong direction.
(c)
1,4
(d)
3
6
Align the matchmark on the clutch cover with the one on

the flywheel.
Torque the bolts on the clutch cover in the order shown in
the illustration.
HINT:
Temporarily tighten the No.1 and No.2 bolts.
8
2,5
INSTALL CLUTCH DISC AND CLUTCH COVER ON

FLYWHEEL
1CDFTV Engine:
Insert SST in the clutch disc, and then insert them in the
flywheel.
SST 0930100210
Matchmarks
D00204
2.
CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the diaphragm spring tip alignment.
Maximum nonalignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment.
SST 0933300013
SST
D00205
3.
(a)
(b)
Q05807
APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE

GREASE (NLGI NO.2)
Apply release hub grease to the following parts.
S
Release fork and hub contact point
S
Release fork and push rod contact point
S
Release fork pivot point
Apply clutch spline grease.
S
Clutch disc spline
HINT:
Recommended grease part number 0888701706 (100g).
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CL13
CLUTCH
CLUTCH UNIT
4.
INSTALL RELEASE BEARING AND FORK TO TRANSAXLE

Install the bearing to the release fork, and then install them to
the transaxle.
5.
INSTALL TRANSAXLE TO ENGINE
C50, C250 M/T: See page MX2
S54, S55 M/T: See page MX2
E351 M/T: See page MX2
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INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .
MX1
MX2
MX8
MX23
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .
MX30
MX37
MX38
MX45
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MX1
TROUBLESHOOTING
TROUBLESHOOTING
MX00202

cause of the problem. Check each part in order. If necessary, replace parts.
Symptom
Suspect Area
See page
Noise
1. Oil (Level low)

2. Oil (Wrong)
3. Gear (Worn
(
or damaged)
g )
MX3
MX3
MX
3
MX8
MX8
Oil leakage

2. Gasket (Damaged)
3. Oil seal ((Worn or damaged)
g )
4. ORing (Worn or damaged)
MX3
MX8
MX
8
MX8
MX8

MX45
MX8
MX23
MX30
MX8
MX23
MX30

3 Shift key spring (Damaged)
3.
Jumps out of gear
1. Locking ball spring

s ring (Damaged)
3. Gear (Worn
(
or damaged)
g )
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MX8
MX8
MX
8
MX8
MX8
MX2

MX06E02
COMPONENTS
RH Drive Shaft
Battery
z Snap
Ring
Tray
Engine Wire
BackUp Light Switch Connector

Speed Sensor Connector
87 (890, 64)
46 (470, 34)
39 (400, 29)
Starter
Ground Cable
Clip
64 (650, 47)
39 (400, 29)
Air Cleaner
Case Assembly
with Air Hose
43 (440, 32)
Washer
Control Cable
z Snap
4AFE Engine:
Ring
LH Drive Shaft
43 (440, 32)
Transaxle
216 (2,200, 159)

52 (530, 38)
64 (650, 47)
Lock Nut Cap

87 (890, 64)
z Cotter
12 (120, 9)
Pin
49 (500, 36)
Stiffener Plate
127 (1,300, 94)
12 (120, 9)
Clutch Release Cylinder
z Gasket
Tie Rod End

Engine Mounting
Center Member
z 43 (430, 32)
z 62 (630, 46)
Engine Left
Mounting Bracket
Front and Center
Exhaust Pipes
73 (740, 54)
Hole Plug
72 (730, 53)
Hole Cover
Hole Plug
Front Transport Hook

73 (740, 54)

z Nonreusable part
39 (400, 29)
D09353
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MX3

MX0CZ01
REMOVAL
1.
REMOVE BATTERY AND AIR CLEANER CASE ASSEMBLY WITH AIR HOSE
2.

LINE
Remove the set bolt of the clutch line bracket.
Remove the 2 bolts and disconnect the clutch release cylinder and line.
(a)
(b)
D02142
3.
DISCONNECT ENGINE WIRE FROM CLAMP
Remove the bolt and engine wire clamp from the transaxle.
4.
DISCONNECT BACKUP LIGHT SWITCH AND SPEED
SENSOR CONNECTORS
D02143
5.
Remove the set bolt and disconnect the ground cable from the
transaxle.
6.
DISCONNECT CONTROL CABLE
(c) Disconnect the 2 control cables from the transaxle.
D02144
Starter Set Bolt
7.
REMOVE STARTER SET BOLT
Remove the set bolt of the starter from the transaxle upper side.
8.
BOLTS
D02145
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MX4
9.
D02147
D02146

Remove the 4 bolts, nut and bracket.
Torque:
Nut B : 87 Nm (890 kgfcm, 64 ftlbf)
12. RAISE VEHICLE
NOTICE:
13. REMOVE LH AND RH ENGINE UNDER COVERS
14.
15.
Filler Plug
Oil Level
0 5 mm
DRAIN TRANSAXLE OIL

Capacity: 1.9 liters (2.0 US qts, 1.7 lmp. qts)
REMOVE LH AND RH DRIVE SHAFTS
(See page SA1)
Drain Plug
D08837
16.
(a)
(b)
REMOVE FRONT AND CENTER EXHAUST PIPES

Remove the 3 nuts and 2 gaskets from the exhaust manifold.
Remove the 2 bolts, nuts, gasket and front and center exhaust pipes.
D02149
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MX5
17.
(a)

(b)
(c)

Torque:
D02150
A
B
A
D02151
18.
(a)
(b)
REMOVE STARTER
Disconnect the connector and wire from the starter.
Remove the set bolt of the starter from the lower side.
(c) Remove the starter.
D02152
20.
REMOVE ENGINE REAR MOUNTING BOLT

D02153
21.
REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING

BOLT
Remove the 4 bolts.
Torque:
B
D00193
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MX6

Lower the engine left side and remove the transaxle from the
engine.
HINT:
S
S
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MX7

MX00504
INSTALLATION
HINT:
S
S
Do the road test.
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MX8

MX00606
COMPONENTS
11 (115, 8)
Hole Cover
Control Cable Bracket

25 (250, 18)
29 (300, 22)
Transaxle Case Receiver
Transaxle Case
11 (115, 8)
Magnet
z Oil Seal
z Input Shaft Front Bearing
Output Shaft Cover
z Output Shaft Front Bearing
Bearing Lock Plate
11 (115, 8)

z Nonreusable part
D10268
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MX9
No.1 Shift Fork
25 (250, 18)
Reverse Shift Arm Bracket
Spring Seat
Reverse Shift Fork
Spring
16 (160, 12)
Ball
Snap Ring
No.1 Shift Fork

Shaft
L
17 (175, 13)
25 (250, 18)
Thrust Washer
16 (160, 12)
Ball
No.3 Shift Fork
Reverse Idler Gear

L
Idler Gear Shaft
25 (250, 18)
Shift Head
16 (160, 12)

29 (300, 22)
16 (160, 12)
No.2 Shift Fork

Snap Ring
5th Driven Gear

z Lock Nut
118 (1200, 87)
Input Shaft
Assembly
Spacer
Snap Ring
Shifting Key Spring

27 (280, 20)
x5
Shifting Key
5th Gear
Synchronizer Ring
Shifting Key Spring
No.3 Hub Sleeve
No.3 Clutch Hub

z Nonreusable part
L Precoated part
Snap Ring
Z18280
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MX10
L
BackUp
Light Switch
20 (200, 14)
Control Shaft Cover
40 (410, 30)
z Gasket
L
39 (400, 29)
20 (200, 14)
z Gasket
Bearing
Oil Receiver Pipe
L Lock Ball Assembly
39 (400, 29)

13 (130, 9)

Shaft Assembly
Oil Receiver Pipe
17 (175, 13)
Transmission Case
Filler Plug
39 (400, 29)
z Gasket
z Bushing
Dust Boot
z Oil Seal
29 (300, 22)
Transmission Case
Cover
x 13
z Gasket
Lever Lock Pin
Drain Plug
25 (250, 18)
39 (400, 29)
Control Shaft
Assembly
12 (120, 9)
Selecting Bellcrank
Assembly
x9
18 (185, 13)
12 (120, 9)
Wave Washer
Control Bellcrank Dust Cover
Wave Washer
12 (120, 9)

z Nonreusable part
L Precoated part
D10269
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MX11

MX0D001
DISASSEMBLY
1.
HINT:
Apply molybdenum disulphide lithium base grease.
(See page CL12)
2.
REMOVE BOLT AND SPEED SENSOR
3.
REMOVE BACKUP LIGHT SWITCH
4.
REMOVE CONTROL CABLE BRACKET
Remove the 2 bolts and control cable bracket.
5.
REMOVE CONTROL SHAFT ASSEMBLY
Remove the 2 nuts, wave washer and control shaft assembly.
D07393
6.
(a)
D07394
REMOVE SELECTING BELLCRANK ASSEMBLY

Remove the 2 bolts and selecting bellcrank assembly.
NOTICE:
At the time of reassembly, please refer to the following
item.
Fit the selecting bellcrank assembly pin part with the dust
cover into a groove in the control shift lever.
(b) Remove the control bellcrank dust cover from the selecting bellcrank assembly.
NOTICE:
item.
Apply MP grease to the inside circumferential surface of
the control bellcrank dust cover.
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MX12
7.
(a)
REMOVE CONTROL SHIFT LEVER AND DUST BOOT

Remove the nut and wave washer.
D07395
(b)
D07396
Using a pin punch and hammer, drive out the lever lock
pin.
NOTICE:
item.
When fixing the lever lock pin, properly position the shaft
groove.
(c) Remove the control shift lever and dust boot.
NOTICE:
items.
S
Install the dust boot into a groove in the control shift
lever.
S
Be sure to install the dust boot in the correct direction, as shown in the illustration.
8.
(a)
(b)
D09357
(c)
REMOVE PLUG, LOCK BALL ASSEMBLY AND CONTROL SHAFT COVER ASSEMBLY
Using a hexagon wrench, remove the plug and gasket.
Remove the lock ball assembly.
Sealant:
242 or equivalent
Remove the 4 bolts and control shaft cover assembly with
the gasket.
Sealant:
242 or equivalent
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MX13
9.
D07398
FIPG
Q07840
REMOVE SHIFT AND SELECT LEVER SHAFT ASSEMBLY

(a) Remove the shift and select lever shaft assembly.
NOTICE:
item.
Set the claws of the shift interlock plate into the shift head
part of the gear shift fork shaft securely.
(b) Remove the select spring seat and compression spring
from the shift and select lever shaft assembly.
10. REMOVE TRANSMISSION CASE COVER
(a) Remove the 9 bolts.
(b) Using a brass bar and hammer, carefully tap the projection of the transmission case cover to remove the transmission case cover from the transmission case.
FIPG:
11.
(a)
(b)
(c)
(d)
REMOVE LOCK NUT

Engage the gear to the double meshing.
Using a chisel and hammer, loosen the staked part of the
nut.
Disengage the gear double meshing.
Q05783
Removal
12.
(a)
Installation
SST
Q05825
REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK

Remove the bolt from the No.3 shift fork.
Remove the No.3 hub sleeve with the shift fork.
(b)
HINT:
Using SST and a hammer, drive in the No.3 hub sleeve with the
shift fork.
SST 0963620010
NOTICE:
Align the synchronizer ring slots with the shifting keys.
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MX14
13. INSPECT 5TH GEAR THRUST CLEARANCE

Standard clearance:
0.100.57 mm (0.00390.0024 in.)
Maximum clearance:
0.57 mm (0.0224 in.)
Q02519
Z00658
14. INSPECT 5TH GEAR RADIAL CLEARANCE

Standard clearance:
KOYO made:
0.0150.058 mm (0.00060.0023 in.)
NSK made:
0.0150.056 mm (0.00060.0022 in.)
Maximum clearance:
KOYO made:0.058 mm (0.0023 in.)
NSK made:0.056 mm (0.0022 in.)
15.
(a)
REMOVE NO.3 CLUTCH HUB AND 5TH GEAR

Using 2 screwdrivers and a hammer, tap out the snap
ring.
HINT:
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.25 (0.0886)
2.49 (0.0980)
2.31 (0.0909)
2.55 (0.1004)
2.37 (0.0933)
2.61 (0.1028)
2.43 (0.0957)
Z00659
(b)
Using a screwdriver, remove the key spring.
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MX15
(c)
Engine Side
SST
Install a bolt and washer to the tip of the input shaft and
using SST, remove the No.3 clutch hub.
SST 0995030011
NOTICE:
Select a bolt whose outer diameter is smaller than the
screw hole of the input shaft so that it can be turned easily.
(d) Remove the synchronizer ring, 5th gear and needle roller
bearing.
Q05790

SST 0962862011, 0995040011 (0995704010),
0995060010 (0995100230)
SST
Q07893
HINT:
Using SST, install the 5th driven gear.
SST 0930912020
SST
SST
N00174

18. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.
x5
Q05785
19.
REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT

20. REMOVE SNAP RING FROM NO.2 SHIFT FORK
SHAFT
Q05786
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MX16
21.
(a)
(b)
REMOVE PLUG, SEAT, SPRING AND BALL

Using a hexagon wrench, remove the 3 plugs.
Sealant:
242 or equivalent
Using a magnetic finger, remove the 3 seats, springs and
balls.
Q07842
22.
(a)
(b)
REMOVE TRANSMISSION CASE

Using a plastic hammer, carefully tap the projection of the
transmission case to remove the transmission case from
the transaxle case.
Z00668
FIPG
HINT:
Apply FIPG to the transaxle case, as shown in the illustration.
FIPG:
D07333
D07351
23. REMOVE OIL RECEIVER PIPE

Remove the 2 bolts and oil receiver pipes from the transmission
case.
NOTICE:
items.
S
Prevent the oil receiver pipes from being deformed.
S
Install the oil receiver pipes while placing it against
the transmission case, as shown in the illustration.
24. REMOVE REVERSE IDLER GEAR, THRUST WASHER
AND SHAFT
Q08151
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MX17
25. REMOVE REVERSE SHIFT ARM BRACKET

Remove the 2 bolts and reverse shift arm bracket.
NOTICE:
items.
S
Set the pin on the top of the reverse shift arm into a
groove on the reverse idler gear.
S
Fit the claw of the reverse shift arm bracket with the
notch of the input shaft front bearing.
S
Install the reverse idler gear, thrust washer and shaft,
Align Alignment Mark
D07336
26.
(a)
(b)
Q05789
(c)
REMOVE GEAR SHIFT FORK AND GEAR SHIFT FORK

SHAFT
Using 2 screwdrivers and a hammer, tap out the 3 snap
rings from each gear shift fork shaft.
Remove the 3 bolts from the No. 1 gear shift head, No. 1
and No. 2 gear shift forks.
Sealant:
242 or equivalent
Pull up the No. 3 gear shift fork shaft, remove the No. 2
gear shift fork shaft.
NOTICE:
item.
To avoid the interference of the 2 balls, lift up the No. 3 gear
shift fork shaft at the position shown in the illustration.
D03039
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MX18
(d)
Remove the No. 1 gear shift head.
D03038
(e)
Z00674
Using a magnetic finger, remove the 2 balls from the reverse shift fork.
(f)
Remove the No. 3 gear shift fork shaft and reverse shift
fork.
(g) Pull out the No. 1 gear shift fork shaft.
(h) Remove the No. 1 and No. 2 gear shift forks.
27. REMOVE INPUT AND OUTPUT SHAFTS TOGETHER
FROM TRANSAXLE CASE
28. REMOVE DIFFERENTIAL CASE ASSEMBLY
NOTICE:
item.
Before reassembly, inspect the differential tapered roller
bearing preload. (See page MX42)
29. REMOVE MAGNET FROM TRANSAXLE CASE
30. DISASSEMBLE NO. 3 CLUTCH HUB ASSEMBLY
(a) Using a screwdriver, remove the shifting key spring.
NOTICE:
item.
Position the shifting key springs so that their end gaps are
not aligned.
(b) Remove the 3 No. 3 shifting keys from the No. 3 clutch
hub.
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MX19

MX06G02
INSPECTION
1.
(a)
(b)
WM0064
INSPECT 5TH GEAR SYNCHRONIZER RING

NOTICE:
off after rubbing.
(d)
WM0065

NOTICE:
off after rubbing.
2.
WM0066

hub sleeve.
3.
REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4.
SST
(a)
IF NECESSARY, REPLACE INPUT SHAFT FRONT

BEARING
SST 0961265014
Z00675
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MX20
(b)
Using SST and a press, install a new bearing.

SST 0995060010 (0995100460), 0995070010
(0995107150)
5.

BEARING
Remove the bolt and bearing lock plate.
SST 0930800010
Remove the output shaft front cover.
SST
Q07845
SST
SST
(a)
(b)
(c)
Z00701
Case
Cover
(d) Install the output shaft front cover.

HINT:
Set the projection of the cover into the hollow in the case.
Z00703
(e)
Using SST and a press, install a new bearing.

SST 0995060010 (0995100620), 0995070010
(0995107150)
(f)
Install the bearing lock plate and torque the bolt.
6.
INSTALL TRANSAXLE CASE RECEIVER
Install the transaxle case receiver and torque the bolt.
SST
Q07846
7.
(a)
(b)
SST
(c)
IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL

SEAL
Using a screwdriver, pry out the oil seal.
Using SST, drive in a new oil seal until its surface is flush
with the transaxle case.
SST 0995060010 (0995100400), 0995070010
(0995107150)
Q07847
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MX21
8.
(a)
(b)

spring pin.
(c)
(d)

pin.
Apply sealant to the screw plug threads.
Sealant:
242 or equivalent
Using a hexagon wrench, install the straight screw plug.
Q07850
(e)
(f)
Z00707
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MX22

MX00902
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MX11).
HINT:
Coat all of the sliding and rotating surfaces with gear oil before reassembly.
NOTICE:
S
Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces.
S
Thoroughly clean all components to remove all the loose material.
S
S
Apply FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface.
S
Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must
be removed and reapplied.
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MX23
INPUT SHAFT
INPUT SHAFT
MX00A03
COMPONENTS
Input Shaft
3rd Gear
No.2 Hub Sleeve
Shifting Key
Shifting Key Spring

4th Gear
Synchronizer Ring
Snap Ring
No.2 Clutch Hub
Synchronizer Ring
Snap Ring
Rear Ball Bearing

Q07849
http://vnx.su
MX24
INPUT SHAFT
MX00B03
DISASSEMBLY
1.
3rd Gear
4th Gear
Q05793
INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE

Standard clearance:
3rd gear: 0.100.35 mm (0.00390.0138 in.)
4th gear: 0.100.55 mm (0.00390.0217 in.)
Maximum clearance:
3rd gear: 0.35 mm (0.0138 in.)
4th gear: 0.55 mm (0.0022 in.)
2.
D00328
INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCE

the gear and shaft.
Standard clearance:
KOYO made:
0.015 0.058 mm (0.0006 0.0023 in.)
NSK made:
0.015 0.056 mm (0.0006 0.0022 in.)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 in.)
NSK made: 0.056 mm (0.0022 in.)
3.
REMOVE SNAP RING
4.
SST
Q04983
REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE

ROLLER BEARING, SPACER AND SYNCHRONIZER
RING FROM INPUT SHAFT
(a) Using SST and a press, remove the rear ball bearing.
SST 0995000020
(b) Remove the 4th gear, needle roller bearings, spacer and
synchronizer ring.
5.
REMOVE SNAP RING
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MX25
INPUT SHAFT
6.
REMOVE NO.2 HUB SLEEVE ASSEMBLY, 3RD GEAR,

SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
Using SST and a press, remove the No.2 hub sleeve assembly,
3rd gear, synchronizer ring and needle roller bearings.
SST 0995000020
SST
CM0064
7.

Remove the 3 shifting keys, springs and No.2 hub sleeve from
the No.2 clutch hub.
Q00817
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MX26
INPUT SHAFT
MX00C03
INSPECTION
1.
(a)
(b)
WM0064
INSPECT SYNCHRONIZER RING

NOTICE:
off after rubbing.
(d)
WM0065

Minimum clearance:
3rd gear: 0.65 mm (0.0256 in.)
4th gear: 0.75 mm (0.0295 in.)
NOTICE:
off after rubbing.
2.

hub sleeve.
WM0066
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MX27
INPUT SHAFT
3.
(a)
(b)
CM0066
INSPECT INPUT SHAFT

Part A: 24.885 mm (0.9797 in.)
Part B: 28.985 mm (1.1411 in.)
Part C: 30.985 mm (1.2199 in.)
Part D: 24.985 mm (0.9834 in.)
If the outer diameter is less than the minimum, replace the input
shaft.
(c)

If the runout exceeds the maximum, replace the input shaft.
CM0013
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MX28
INPUT SHAFT
MX00D03
REASSEMBLY
HINT:
reassembly.
1.
INSTALL NO.2 CLUTCH HUB INTO NO.2 HUB SLEEVE
(a) Install the 3 springs and shifting keys to the No.2 clutch
hub.
(b) Install the No.2 hub sleeve to the No. 2 clutch hub.
Front
Side
Q00909
2.
INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,

SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
slots with shifting keys.
(a)
(b)
Q02522
(c)
Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3.
(a)
INSTALL SNAP RING

N00067
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.30 (0.0906)
2.48 (0.0976)
2.36 (0.0929)
2.54 (0.1000)
2.42 (0.0953)
2.60 (0.1024)
(b)
4.

INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX24)
5.
INSPECT SYNCHRONIZER RING, NEEDLE ROLLER

BEARING, SPACER, 4TH GEAR AND REAR BALL
BEARING
N00068
(a)
(b)
Q02525
http://vnx.su
MX29
INPUT SHAFT
(c)

SST 0960803071
6.
(a)
INSTALL SNAP RING

SST
SM0049
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.29 (0.0902)
2.47 (0.0972)
2.35 (0.0925)
2.53 (0.0996)
2.41 (0.0949)
2.59 (0.1020)
(b)
7.
SM0050

INSPECT 4TH GEAR THRUST CLEARANCE
(See page MX24)
http://vnx.su
MX30
OUTPUT SHAFT
OUTPUT SHAFT
MX00E03
COMPONENTS
Ball
Output shaft
Thrust Washer
Synchronizer Ring
1st Gear
No.1 Clutch Hub
Synchronizer Ring
No.1 Hub Sleeve
Snap Ring
Shifting Key Spring
Shifting Key
Spacer
2nd Gear
Output Gear Spacer

4th Driven Gear
Rear Ball Bearing
3rd Driven Gear
Q07853
http://vnx.su
MX31
OUTPUT SHAFT
MX00F03
DISASSEMBLY
1.
2nd Gear
1st Gear
Q05794
INSPECT 1ST AND 2ND GEARS THRUST CLEARANCES

Standard clearance:
1st gear: 0.100.40 mm (0.00390.0157 in.)
2nd gear: 0.100.45 mm (0.00390.0177 in.)
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.45 mm (0.0177 in.)
2.
SM0137
INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE

the gear and shaft.
Standard clearance:
KOYO made:
0.015 0.058 mm (0.0006 0.0023 in.)
NSK made:
0.015 0.056 mm (0.0006 0.0022 in.)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 in.)
NSK made: 0.056 mm (0.0022 in.)
3.
SST
(a)
(b)
REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR

AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
Using SST and a press, remove the ball bearing and 4th
driven gear.
SST 0995000020
Remove the output spacer.
CM0065
http://vnx.su
MX32
4.
(a)
OUTPUT SHAFT
REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE

ROLLER BEARING, SYNCHRONIZER RING AND
SPACER
Shift the No.1 hub sleeve into the 1st gear.
N00074
(b)
Using SST and a press, remove the 3rd driven gear.

SST 0995000020
(c) Remove the 2nd gear, needle roller bearing, synchronizer
ring and spacer.
5.
REMOVE SNAP RING
SST
MT0063
6.
(a)
(b)
REMOVE NO.1 HUB SLEEVE ASSEMBLY 1ST GEAR,

SYNCHRONIZER RING, NEEDLE ROLLER BEARING,
THRUST WASHER AND BALL
Using a press, remove the No.1 hub sleeve assembly, 1st
gear and synchronizer ring.
Remove the needle roller bearing, thrust washer and ball.
N00076
7.

Remove the 3 shifting keys, springs and No.1 hub sleeve from
the No.1 clutch hub.
Q00818
http://vnx.su
MX33
OUTPUT SHAFT
MX0D101
INSPECTION
1.
(a)
(b)
WM0064

NOTICE:
off after rubbing.
(d)
WM0065

NOTICE:
off after rubbing.
2.
(a)
(b)

D07357
(c)

D07358
http://vnx.su
MX34
OUTPUT SHAFT
3.
INSPECT GEAR SHIFT FORK AND REVERSE GEAR

CLEARANCE
Using a feeler gauge, measure the clearance between the reverse gear and gear shift fork.
If the clearance exceeds the maximum, replace the gear shift
fork or hub sleeve.
WM0066
4.
(a)
(b)
MT0071

Check the output shaft for wear or damage.
Part A: 32.985 mm (1.2986 in.)
Part B: 37.985 mm (1.4955 in.)
Part C: 31.985 mm (1.2592 in.)
If the outer diameter is less than the minimum, replace the output shaft.
(c) Using a dial indicator, check the shaft runout.
If the runout exceeds the maximum, replace the output shaft.
CM0015
http://vnx.su
MX35
OUTPUT SHAFT
MX00H03
REASSEMBLY
HINT:
reassembly.
1.
INSTALL NO.1 CLUTCH HUB INTO NO.1 HUB SLEEVE
(a) Install the 3 springs and shifting keys to the No.1 clutch
hub.
(b) Install the No.1 clutch hub to the No.1 hub sleeve.
Front
Side
Q00819
2.
INSTALL BALL, THRUST WASHER, 1ST GEAR,

NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
Install the ball to the shaft.
Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
Install the needle roller bearing, 1st gear and synchronizer ring.
Place the synchronizer ring on the gear and align the
clutch hub grooves with the projections on the synchronizer ring.
(a)
(b)
Notch
Q00805
(c)
(d)
(e)
Q00908
(f)
Using a press, install the 1st gear and No.1 hub sleeve.
3.
(a)
INSTALL SNAP RING

N00079
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.50 (0.0984)
2.68 (0.1055)
2.56 (0.1008)
2.74 (0.1079)
2.62 (0.1031)
2.80 (0.1102)
(b)
4.
N00080

INSPECT 1ST GEAR THRUST CLEARANCE
(See page MX31)
http://vnx.su
MX36
5.
(a)
Q00806
(b)
(c)
(d)
OUTPUT SHAFT
INSTALL SYNCHRONIZER RING, SPACER, NEEDLE

ROLLER BEARING, 2ND GEAR AND 3RD DRIVEN
GEAR
Place the synchronizer ring on the gear and align the
clutch hub grooves with the projections on the synchronizer ring.
Install the spacer.
Install the 2nd gear.
(e)
6.
Using a press, install the 3rd driven gear.

INSPECT 2ND GEAR THRUST CLEARANCE
(See page MX31)
7.
INSTALL OUTPUT GEAR SPACER AND 4TH DRIVEN

GEAR
Install the output gear spacer.
Using a press, install the 4th driven gear.
Z00711
(a)
(b)
Z00712
8.
INSTALL REAR BALL BEARING
SST 0931660011 (0931600021)
SST
Z00713
http://vnx.su
MX37

MX00I06
COMPONENTS

Shaft
Snap Ring
Compression Spring
Select Inner Lever
Shift Interlock
Plate
No. 2 Shift Inner
Lever
No. 2 Select Spring

Seat
Slotted Spring Pin
Slotted Spring Pin

Compression Spring
ERing
Slotted Spring Pin
Apply MP grease
D07696
http://vnx.su
MX38
DIFFERENTIAL CASE
DIFFERENTIAL CASE
MX00J03
COMPONENTS
z Outer Race and Side Bearing
z Oil Seal
Ring Gear
Pinion Gear
Shim
Pinion Shaft
77 (790, 57)
x8
z Side Bearing and Outer Race
Side Gear
Shim
Side Gear Thrust Washer
Differential Case
Straight Pin
Speed Sensor Drive Gear
z Nonreusable part
z Oil Seal
Z17126
http://vnx.su
MX39
DIFFERENTIAL CASE
MX00K03
DISASSEMBLY
Matchmarks
1.
(a)
(b)
(c)
REMOVE RING GEAR

Place matchmarks on the ring gear and case.
Remove the 8 bolts.
it from the case.
2.
Speed Sensor Drive Gear Side:

CASE
Using SST, remove the side bearing.
SST 0995000020, 0995000030, 0995060010
(0995100360)
D00855
(a)
SST
Z16131
SST
Q07848
Q00807
HINT:
where the speed sensor drive gear is indented.
(b) Remove the speed sensor drive gear.
3.
Ring Gear Side:
CASE
Using SST, remove the side bearing.
SST 0995000020, 0995000030, 0995060010
(0995100360)
HINT:
where the differential case is indented.
4.
while holding one pinion toward the case.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
5.
(a) Using a pin punch and hammer, drive out the straight pin.
(b) Remove the pinion shaft from the case.
(c) Remove the 2 pinions and side gears with the 4 thrust
http://vnx.su
MX40
6.
SST
(a)
(b)
(c)
DIFFERENTIAL CASE

IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
Using SST, pull out the outer race and shim.
SST 0961265014
N00098
(d)
Using SST and a hammer, drive in a new outer race.

SST 0995060020 (0995100710), 0995070010
(0995107150)
(e)

SST 0935032014 (0935132111, 0935132130)
SST
Q08120
9.9 0.3 mm
SST
(f)
Q08121
7.
(a)
(b)
SST
(c)

IF NECESSARY, REPLACE OIL SEAL AND SIDE
BEARING OUTER RACE
Using SST, pull out the outer race and shim.
SST 0961265014
N00100
(d)
Using SST and a hammer, drive in a new outer race.

SST 0995060020 (0995100680), 0995070010
(0995107150)
SST
Z16127
http://vnx.su
MX41
(e)
1.9 0.3 mm
(f)
DIFFERENTIAL CASE

SST 0935032014 (0935132130, 0935132150)
SST
Z02714
http://vnx.su
MX42
DIFFERENTIAL CASE
MX00L03
REASSEMBLY
1.
(a)

Install the correct thrust washers and side gears. Refer to
the table below, select thrust washers which will allow that
the backlash is within the specification.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
Thickness mm (in.)
Thickness mm (in.)
0.95 (0.0374)
1.10 (0.0433)
1.00 (0.0394)
1.15 (0.0453)
1.05 (0.0413)
1.20 (0.0472)
N00102
(b)
(c)

case.
(d)
Q00807
Using a dial indicator, check the side gear backlash. Measure the side gear backlash while holding one pinion gear
toward the case.
Standard backlash:
0.05 0.20 mm (0.0020 0.0079 in.)
(e) Using a pin punch and hammer, drive in the straight pin
through the case and hole in the pinion shaft.
(f)
Stake the differential case.
2.
Ring Gear Side:
INSTALL SIDE BEARING
Using SST and a press, install a new side bearing.
SST 0955010013 (0925210010, 0955610011)
SST
Z00728
3.
(a)
Speed Sensor Drive Side:

INSTALL SIDE BEARING
Install the speed sensor drive gear.
Case Side
Q00808
http://vnx.su
MX43
(b)
SST
4.
(a)
(b)
(c)
(d)
SST
Z00729
DIFFERENTIAL CASE
Using SST and a press, install a new side bearing.

SST 0955010013 (0955610011), 0995060010
(0995100460), 0995070010 (0995107150)
Clean the contact surface of the differential case.
Heat the ring gear in boiling water.
Carefully take the ring gear out of the water.
After the moisture on the ring gear has completely evaporated, quickly install the ring gear to the differential case.
HINT:
Align the matchmarks on the differential case and contact the
ring gear.
(e) Temporarily install the 8 set bolts.

NOTICE:
The ring gear set bolts should not be tightened until the
ring gear has cooled sufficiently.
(f)
gear set bolts uniformly at a time.
Case
Side
Q08183
5.
(a)
(b)
(c)
INSPECT DIFFERENTIAL SIDE BEARING PRELOAD

Install the differential case assembly to the transaxle
case.
Install the transmission case.
Install and torque the case bolts.
CM0061
http://vnx.su
MX44
DIFFERENTIAL CASE
(d)
SST
MT0092
Using SST and a torque wrench, measure the preload.

SST 0956432011
New bearing
0.8 1.6 Nm (8 16 kgfcm, 6.9 13.9 in.lbf)
Reused bearing
0.5 1.0 Nm (5 10 kgfcm, 4.3 8.7 in.lbf)
If the preload is not within the specification, remove the transmission case side outer race of the side bearing with SST.
(See page MX39)
Select another shim.
HINT:
The preload will change by about 0.3 0.4 Nm (3 4 kgfcm,
2.6 3.5 in.lbf) with each 0.05 mm change in shim thickness.
Mark
Thickness mm (in.)
Mark
Thickness mm (in.)
2.10 (0.0827)
2.60 (0.1024)
2.15 (0.0846)
2.65 (0.1043)
2.20 (0.0866)
2.70 (0.1063)
2.25 (0.0886)
2.75 (0.1083)
2.30 (0.0906)
2.80 (0.1102)
2.35 (0.0925)
2.85 (0.1122)
2.40 (0.0945)
2.90 (0.1142)
2.45 (0.0965)
2.95 (0.1161)
2.50 (0.0984)
3.00 (0.1181)
2.55 (0.1004)
http://vnx.su
MX45

MX06H02
COMPONENTS
Parking Brake Cover
Shift Lever Knob


Cap
12 (120, 9)
Clip
Cap
Air Duct
4.9 (50, 43in.lbf)

Shift Control Cable
Clip
Clip
Clip
Washer
Shift Cable Grommet
Shift Cable Grommet
Retainer
Washer
Clip
Heat Insulator
4.9 (50, 43in.lbf)
Washer
43 (430, 32)
z Gasket
z Rivet
z
z
z
zGasket
z
62 (630, 46)
z
Exhaust Pipe

z Nonreusable part
D09354
http://vnx.su
http://vnx.su

VNX - Su Avensis Supplement Chassis Body 2000 rm781 PDF

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VNX - Su Avensis Supplement Chassis Body 2000 rm781 PDF

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FOREWORD

ZZT220, 221 series

AVENSIS/CORONA Chassis and Body Repair Manual

AVENSIS/CORONA Chassis and Body Repair Manual Supplement (Aug., 1999)

1ZZFE, 3ZZFE Engine Repair Manual

1AZFSE Engine Repair Manual

3SFE Engine Repair Manual

3SFE Engine Repair Manual Supplement (Jan., 1996)

3SFE Engine Repair Manual Supplement (Oct., 1997)

1CDFTV Engine Repair Manual

A245E Automatic Transaxle Repair Manual

U240E Automatic Transaxle Repair Manual

AVENSIS/CORONA Electrical Wiring Diagram

AVENSIS/CORONA Electrical Wiring Diagram Supplement (May, 1999)

AVENSIS/CORONA Electrical Wiring Diagram Supplement (Jul., 2000)

AVENSIS/CORONA New Car Features

AVENSIS/CORONA New Car Features Supplement

TOYOTA Model New Car Features Supplement

TOYOTA MOTOR CORPORATION

2000 TOYOTA MOTOR CORPORATION

MANUAL TRANSAXLE (E351)

PROBLEM SYMPTOMS TABLE

1. Oil (Level low)

1. Oil (Level too high)

1. Control cable (Faulty)

Hard to shift or will not shift

Jumps out of gear

1. Locking ball spring (Damaged)

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT

MANUAL TRANSAXLE UNIT

Air Cleaner Case

Air Flow Meter

4.9 (50, 43 in.lbf)

Intake Air Temperature

Diesel Throttle Body

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT

8.0 (82, 71in.lbf)

216 (2,200, 159)

Lock Nut Cap

Tie Rod End

127 (1,300, 94)

Bolt with Spring

RH Engine Under Cover

Nm (kgfcm, ftlbf) : Specified torque

LH Engine Under Cover

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT

REMOVE BATTERY AND TRAY

REMOVE NO.1 AIR TUBE ASSEMBLY

Remove the 2 bolts as shown in the illustration.

Remove the 2 bolts as shown in the illustration.

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT

DISCONNECT CLUTCH RELEASE CYLINDER AND

REMOVE 4 TRANSAXLE UPPER SIDE MOUNTING

12. INSTALL ENGINE SUPPORT FIXTURE

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT

REMOVE ENGINE LEFT MOUNTING BRACKET 3 SET

14. REMOVE ENGINE LEFT MOUNTING BRACKET

DRAIN TRANSAXLE OIL

REMOVE ENGINE MOUNTING CENTER MEMBER

AVENSIS/CORONA SUP (RM781E)

MANUAL TRANSAXLE UNIT