Yaris 2007 service manual part 01

Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01 Yaris 2007 service manual part 01

INTRODUCTION – HOW TO USE THIS MANUAL IN–1

(3) Final Inspection(b) The following procedures are omitted from this manual However, these procedures must be performed

(1) Use a jack or lift to perform operations(2) Clean all removed parts

(3) Perform a visual check

2 INDEX

(a) An alphabetical INDEX section is provided at the end of the manual as a reference to help you find the item to be repaired

3 PREPARATION

(a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure Be sure to use SST and SSM when they are required and follow the working procedure properly A list of SST and SSM is in the "Preparation" section of this manual

4 REPAIR PROCEDURES

(a) A component illustration is placed under the title where necessary

IN–4 INTRODUCTION – IDENTIFICATION INFORMATION

IN

IDENTIFICATION INFORMATION

VEHICLE IDENTIFICATION AND SERIAL NUMBERS

1 VEHICLE IDENTIFICATION NUMBER

(a) The vehicle identification number is stamped on the vehicle body and on the certification label, as shown

A:

1NZ-FE B:

U340E C:

B

B126436E01

INTRODUCTION – REPAIR INSTRUCTION IN–5

IN

REPAIR INSTRUCTION

PRECAUTION

1 BASIC REPAIR HINT

(a) HINTS ON OPERATIONS

2

operation.

fumes in the workshop.

wear appropriate safety equipment and take extra care not to injure yourself or others.

stand.

5

Removal and installation,

disassembly and assembly

operations

problem.

deformation and damage.

electrical connections, bolts, or hoses removed Add matchmarks to insure reassembly of components in the original positions Temporarily mark hoses and their fittings if needed.

check.

or contaminating the new parts.

with new ones as instructed in this manual.

1

2

3 4

5

6

3

B124459E01

INTRODUCTION – REPAIR INSTRUCTION IN–21

(a) The vehicle must be unloaded before jacking up/

lifting up the vehicle Never jack up/lift up a heavily loaded vehicle

(b) When removing heavy parts such as the engine and transaxle, the center of gravity of the vehicle may shift To stabilize the vehicle, place a balance weight

in a location where it will not roll or shift, or use a mission jack to hold the jacking support

2 NOTICE FOR USING 4 POST LIFT

(a) Follow the safety procedures outlined in the lift instruction manual

(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels

(c) Using a wheel stopper, secure the vehicle

3 NOTICE FOR USING JACK AND SAFETY STAND

(a) Work in a flat area and use a wheel stopper at all times

(b) Use safety stand with a rubber attachment, as shown in the illustration

(c) Apply the jack and rigid rack to the specified location on the vehicle The jack should not be used without the rigid rack

(d) When jacking up the front wheels, release the parking brake and place wheel stoppers only behind the rear wheels When jacking up the rear wheels, place wheel stoppers only in front of the front wheels

(e) When jacking up only the front wheels or only the rear wheels, place wheel stoppers on both sides of the wheels touching the ground

(f) When lowering a vehicle with its front wheels jacked

up, release the parking brake and place wheel stoppers only in front of the rear wheels When lowering a vehicle with its rear wheels jacked up, place wheel stoppers only behind the front wheels

INTRODUCTION – REPAIR INSTRUCTION IN–25

PASSIVE MODE

(Passive Arming Mode)

deterrent system switched from arming preparation state to armed state 30 seconds after both of following operations performed.

key cylinder

In passive arming mode, if following operations are not performed within 14 seconds of door being opened while in armed state, theft deterrent system determines that condition as theft and switches to alarm arming sounding state.

cylinder and ignition switch turned from OFF to ON

ON/OFF

WARNING (HORN)

(Warning horn)

horn to be used as warning devices

ON/OFF

before warning starts) for passive arming mode

0 /14 /30 (seconds)

LIGHTING TIME

(Lighting Time)

after door closure.

(It will quickly fade out in case of turning the ignition switch ON.)

7.5 seconds / 15 seconds / 30seconds

I/L ON /ACC OFF

(Room light illuminates when

ignition switch turned off)

switch turned on (ACC).

(Room light illuminated when interior light switch in DOOR position)

ON / OFF

I/L ON / UNLOCK

(Room light illuminates when

door key unlocked.)

when unlocking with the door key cylinder.

(Room light illuminated when interior light switch in DOOR position)

ON/OFF

IN–26 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

be very intricate, requiring a high level of technical knowledge

to troubleshoot However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs

FOR USING INTELLIGENT TESTER

• Before using the intelligent tester, read the tester operator's manual thoroughly

• If the tester cannot communicate with the ECU controlled systems when the tester is connected to the DLC3 with the engine switch on (IG) and the tester turned ON, there is a problem on the vehicle side or tester side

(a)If communication is normal when the tester is connected to another vehicle, inspect the diagnosis data link line (Bus (+) line) or ECU power circuit of the vehicle

(b)If communication is still not possible when the tester is connected to another vehicle, the problem is probably

in the tester itself Perform the Self Test procedures outlined in the tester operator's manual

INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS IN–35

at high temperatures, i.e immediately after the vehicle has been running Measurements should

be made after the engine has cooled down

(b) HANDLING CONNECTORS(1) When disconnecting a connector, first squeeze the mating halves tightly together to release the lock, and then press the lock claw and separate the connector

(2) When disconnecting a connector, do not pull on the harnesses Grasp the connector directly and separate it

(3) Before connecting a connector, check that there are no deformed, damaged, loose or missing terminals

(4) When connecting a connector, press firmly until

it locks with a "click" sound

(5) If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead

NOTICE:

• As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness.

• Do not damage the terminals by moving the inserted tester needle.

(c) CHECKING CONNECTORS(1) Checking when a connector is disconnected:

Squeeze the connector together to confirm that they are fully connected and locked

(2) Checking when a connector is disconnected:

Check by pulling the wire harness lightly from the backside of the connector Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals

Looseness of

Crimping

D025087E03

IN–40 INTRODUCTION – TERMS

IN

TERMS

ABBREVIATIONS USED IN MANUAL

IN–46 INTRODUCTION – TERMS

Electrically Erasable Programmable Read Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM)

-PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM PP–1

PREPARATION – 1NZ-FE ENGINE CONTROL SYSTEM PP–3

PP–2 PREPARATION – 1NZ-FE ENGINE MECHANICAL

Replacer Set

Replacer 5

PREPARATION – 1NZ-FE ENGINE MECHANICAL PP–5

PP

RECOMMENDED TOOLS

PREPARATION – 1NZ-FE ENGINE MECHANICAL PP–7

PREPARATION – 1NZ-FE FUEL PP–7

PP

PREPARATION

1NZ-FE FUEL

SST

PREPARATION – 1NZ-FE FUEL PP–9

PP

RECOMMENDED TOOLS

PREPARATION – 1NZ-FE FUEL PP–11

PP

SSM

(FIPG)

PP–10 PREPARATION – 1NZ-FE EMISSION CONTROL

PP–12 PREPARATION – 1NZ-FE EMISSION CONTROL

PREPARATION – 1NZ-FE EXHAUST PP–11

PP–12 PREPARATION – 1NZ-FE COOLING

PP

PREPARATION

1NZ-FE COOLING

SST

PP–14 PREPARATION – 1NZ-FE COOLING

PP

COOLANT

Engine Coolant

quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids) A/T

4.7 liters (5.0 USqts, 4.4 lmp qts)

PREPARATION – 1NZ-FE LUBRICATION PP–13

PREPARATION – 1NZ-FE LUBRICATION PP–15

PP

LUBRICANT

PREPARATION – 1NZ-FE IGNITION PP–15

PP

PREPARATION

1NZ-FE IGNITION

RECOMMENDED TOOLS

PP–16 PREPARATION – 1NZ-FE STARTING

PREPARATION – 1NZ-FE CHARGING PP–17

Wrench

PREPARATION – 1NZ-FE CHARGING PP–19

PP–18 PREPARATION – U340E AUTOMATIC TRANSAXLE

PP

PREPARATION

U340E AUTOMATIC TRANSAXLE

SST

PP–24 PREPARATION – U340E AUTOMATIC TRANSAXLE

PP–26 PREPARATION – U340E AUTOMATIC TRANSAXLE

PP

LUBRICANT

Automatic transaxle fluid

& Replacer

PREPARATION – CLUTCH PP–27

PP

LUBRICANT

PP–26 PREPARATION – C50 MANUAL TRANSAXLE

PP

PREPARATION

C50 MANUAL TRANSAXLE

SST

Replacer

PREPARATION – C50 MANUAL TRANSAXLE PP–31

PREPARATION – C50 MANUAL TRANSAXLE PP–33

PP

LUBRICANT

SAE 75W

PP–32 PREPARATION – DRIVE SHAFT

PP

PREPARATION

DRIVE SHAFT

SST

Puller

PP–34 PREPARATION – DRIVE SHAFT

PP

EQUIPMENT

Torque wrench

Replacer

PP–40 PREPARATION – SUSPENSION

PP

RECOMMENDED TOOLS

PP–40 PREPARATION – TIRE AND WHEEL

PP

PREPARATION

TIRE AND WHEEL

EQUIPMENT

Dial indicator with magnetic base

Tire pressure gauge

Wheel balancer

PREPARATION – BRAKE CONTROL PP–41

PP

PREPARATION

BRAKE CONTROL

SST

PREPARATION – BRAKE CONTROL PP–43

PP

EQUIPMENT

Torque wrench

Dial indicator with magnetic base

Brake drum gauge

Slide caliper

PREPARATION – PARKING BRAKE PP–43

PP–44 PREPARATION – STEERING COLUMN

PP–46 PREPARATION – STEERING COLUMN

PP

EQUIPMENT

Torque wench

Drill

PREPARATION – POWER STEERING PP–45

PP

PREPARATION

POWER STEERING

SST

PREPARATION – POWER STEERING PP–47

PP

EQUIPMENT

Torque wrench

PP–46 PREPARATION – AIR CONDITIONING

PP

PREPARATION

AIR CONDITIONING

SST

-PP–48 PREPARATION – AIR CONDITIONING

PP–48 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM

PP

PREPARATION

SUPPLEMENTAL RESTRAINT SYSTEM

SST

PP–50 PREPARATION – SUPPLEMENTAL RESTRAINT SYSTEM

Service-purpose wire harness

Shop rag or pice of cloth

PP–50 PREPARATION – SEAT BELT

PP

PREPARATION

SEAT BELT

SST

Sub-harness No.5

PP–52 PREPARATION – SEAT BELT

Service-purpose wire harness

Service wire harness

Tire with wheel

Torque wrench

PREPARATION – THEFT DETERRENT SYSTEM PP–51

PP

PREPARATION

THEFT DETERRENT SYSTEM

RECOMMENDED TOOLS

PP–52 PREPARATION – ENGINE IMMOBILISER

PP

PREPARATION

ENGINE IMMOBILISER

RECOMMENDED TOOLS

PREPARATION – CRUISE CONTROL PP–53

PP

PREPARATION

CRUISE CONTROL

RECOMMENDED TOOLS

PREPARATION – WIPER AND WASHER PP–55

PP

PREPARATION

WIPER AND WASHER

RECOMMENDED TOOLS

PP–56 PREPARATION – DOOR LOCK

PP–58 PREPARATION – DOOR LOCK

-PP–58 PREPARATION – AUDIO / VISUAL

PP–60 PREPARATION – OTHER SYSTEM

PREPARATION – WINDSHIELD / WINDOWGLASS PP–61

PREPARATION – WINDSHIELD / WINDOWGLASS PP–63

PP

SSM

or equivalent

PREPARATION – INSTRUMENT PANEL PP–63

PREPARATION – ENGINE HOOD / DOOR PP–65

PREPARATION – ENGINE HOOD / DOOR PP–67

PP–68 PREPARATION – CAN COMMUNICATION

PP

PREPARATION

CAN COMMUNICATION

RECOMMENDED TOOLS

SERVICE SPECIFICATIONS – STANDARD BOLT SS–1

SERVICE SPECIFICATIONS – STANDARD BOLT SS–3

SS

HOW TO DETERMINE NUT STRENGTH

Nut Type

HINT:

• *: Nut with 1 or more marks on one side surface of the nut

• Use the nut with the same number of the nut strength classification or greater than the bolt strength classification number when tightening parts with a bolt and nut

Example:

• Bolt = 4T

• Nut = 4N or more

SS–4 SERVICE SPECIFICATIONS – 1NZ-FE ENGINE CONTROL SYSTEM

SS

1NZ-FE ENGINE CONTROL SYSTEM

SERVICE DATA

A4 - C1

Below 1 Ω (Apply battery voltage between terminals A2 and A3)

Accelerator pedal position No 1 standard

voltage

Standard resistance Accelerator pedal released Accelerator pedal depressed

0.5 to 1.1 V 2.6 to 4.5 V

Accelerator pedal position No 2 standard

voltage

Standard resistance Accelerator pedal released Accelerator pedal depressed

1.2 to 2.0 V 3.4 to 5.0 V

SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL SS–5

SS

1NZ-FE ENGINE MECHANICAL

SERVICE DATA

Exhaust

0.15 to 0.25 mm (0.006 to 0.010 in.) 0.25 to 0.35 mm (0.010 to 0.014 in.)

Camshaft timing gear diameter (w/

Camshaft timing sprocket diameter (w/

Maximum

143.5 mm (5.6496 in.) 144.2 mm (5.6772 in.)

Cylinder head warpage

Maximum cylinder block surface Intake manifold surface Exhaust manifold surface

0.05 mm (0.0020 in.) 0.10 mm (0.0039 in.) 0.10 mm (0.0039 in.)

Minimum

89.25 mm (3.5138 in.) 88.75 mm (3.4941 in.)

Minimum

1.0 mm (0.039 in.) 0.5 mm (0.020 in.)

Minimum

87.90 mm (3.4606 in.) 87.40 mm (3.4409 in.)

Minimum

1.15 mm (0.045 in.) 0.5 mm (0.020 in.)

Valve spring installed tension at 32.5 mm

Valve spring working tension at 23.9 mm

Valve guide bushing oil clearance

Standard intake Standard exhaust

0.025 to 0.060 mm (0.0010 to 0.0024 in.) 0.030 to 0.065 mm (0.0012 to 0.0026 in.) Maximum intake

Maximum exhaust

0.08 mm (0.0032 in.) 0.10 mm (0.039 in.)

O/S

9.685 to 9.706 mm (0.3813 to 0.3821 in.) 9.735 to 9.755 mm (0.3833 to 0.3841 in.)

SS–8 SERVICE SPECIFICATIONS – 1NZ-FE ENGINE MECHANICAL

SS

TORQUE SPECIFICATIONS

Stud bolt x Cylinder head assembly

Fuel delivery pipe subassembly x Cylinder head

assembly

Bolt A Bolt B

19 9.0

194 92

14

80 in.*lbf

Cylinder head assembly x Cylinder block assembly

1st 2nd 3rd

29 Turn 90°

Turn 90°

300 Turn 90°

Turn 90°

22 Turn 90° Turn 90°

Bolt B Bolt C Bolt D

5.0 5.0 11 5.0

51 51 112 51

44 in.*lbf

44 in.*lbf 8.1

44 in.*lbf

oil pump assembly x Cylinder head & block

Bolt A Bolt B Bolt C Nut D Bolt E

32 11 11 24 24

326 112 112 245 245

24 8.1 8.1 18 18

SERVICE SPECIFICATIONS – 1NZ-FE FUEL SS–9

SS

1NZ-FE FUEL

SERVICE DATA

Fuel pressure : at fuel pressure remains for 5

Fuel injector assembly

Connect

SS–10 SERVICE SPECIFICATIONS – 1NZ-FE EMISSION CONTROL

SERVICE SPECIFICATIONS – 1NZ-FE EXHAUST SS–11

SS–12 SERVICE SPECIFICATIONS – 1NZ-FE COOLING

SS

1NZ-FE COOLING

SERVICE DATA

Cooling fan relay No.2

Standard resistance

Standard resistance B5 - B8

Below 1 Ω (Apply battery voltage between terminals B6 and B7)

Cooling fan relay

3-4(When battery voltage applied to terminals

3-5 (When battery voltage applied to

Radiator cap sub-assembly

to 17.8 psi)

SERVICE SPECIFICATIONS – 1NZ-FE LUBRICATION SS–13

SS

1NZ-FE LUBRICATION

SERVICE DATA

rpm

Oil pump rotor set

Standard tip clearance Maximum tip clearance Standard body clearance Maximum body clearance

0.060 to 0.180 mm (0.0024 to 0.0071 in.) 0.28 mm (0.0110 in.)

0.250 to 0.325 mm (0.0098 to 0.0128 in.) 0.425 mm (0.0167 in.)

SS–14 SERVICE SPECIFICATIONS – 1NZ-FE IGNITION

SS

1NZ-FE IGNITION

SERVICE DATA

Spark plug

IFR5A 11 NGK made

for used spark plug

for new spark plug

SERVICE SPECIFICATIONS – 1NZ-FE STARTING SS–15

10 kΩ or higher Below 1 Ω (Apply battery voltage between terminals B2 and B3)

10 kΩ or higher (LOCK) Standard resistance

2 - 4

Below 1 Ω (ACC) Standard resistance

(ON) Standard resistance

5 - 6 Standard resistance

(START) Standard resistance

5 - 6 - 7

Starter armature assembly commutator

Starter armature assembly commutator

diameter